CZ2000859A3 - Door frame assembly - Google Patents

Abstract

Door frame assembly (1) for door mounting and the like includes a pair of posts (2, 3), an upper portion (4) for connection of the columns and the threshold (5). Each of these columns (2, 3) and the top and the sill are molded from the mixed material. Each the columns (2) and (3) and the upper part (4) are molded into shape oblong box construction. The posts are oblong the side walls (9) and the end walls (10) and the top part (4) having elongated side walls (11) and end walls (12). Inside each of said columns (2, 3) is divided in the middle a longitudinally extending wall (17) which divides the interior of the posts (2, 3) on two adjacent channels (17a, 17b).

Description

Technical field

The present invention relates to door frames and frame members from which the frames are assembled.

BACKGROUND OF THE INVENTION

Currently, most door frames are made of wood, which frames include a pair of pillar elements and an upper part (lintel). In the case of external doors, the frame also includes a door sill, while in the case of internal doors the posts extend to the floor.

In the case of large volumes, door elements (

The frames are manufactured at the factory in a ready-to-assemble condition, or in some cases at the factory. Often, however, the door frame elements are cut from the blank at the assembly site and drilled and milled to form the fastening and hinged mounting regions and then seated in the appropriate position for each individual door.

In addition to wooden there are. also door frames of other materials or of a combination of other materials and wood.

US Patent 1,606,780, issued November 16, 1926, discloses a metal door frame.

U.S. Patent 4,281,481, issued August 4, 1981, discloses a 25 aluminum door frame, while U.S. Patent 3,287,856, issued October 16, 1964 discloses an extruded metal frame.

US Patent 4,531,337, issued July 30, 1985, discloses a door frame of a combination of metal and wood, while US Patent 4,505,080, issued March 19, 1985, discloses a door frame. Frame made of a combination of extruded metal or plastic and wood. U.S. Patent 5,293,723. issued March 15, 1994, then discloses a door frame of a combination of plastic and wood.

In the case of wooden door frames, not only is the wood relatively expensive, but the wood elements from which the frame is made are subjected to torsion and deformation, which adversely affects the accuracy of the entire frame.

Metal frames, on the other hand, do not offer easy adjustment according to the wall opening receiving the frame. In addition, these frames are expensive and also usually include assembly with certain wood parts. In addition, metal is a good heat conductor and hence poor insulation.

Extruded plastic frame elements do not have their own wood strength and cannot easily be secured without the use of wood inserts.

European Patent Application 0-586213 A1, published March 9, 1994, discloses a hollow window or door structural component that can be extruded or injection molded from polymer and wood fiber. However, by being extrudable, the walls of this hollow component have uniform dimensions over their entire length and the component is open at the ends. Such components can be joined at right angles by diagonally cutting and welding their ends, but they do not provide mutually matching bearing arrangements.

US Patent 4,154,034, issued May 15, 1979, discloses generally J-shaped door frame components that are formed of glass fiber reinforced polystyrene. However, these components assume an upward, curved tip of the lower part of the letter J as a door • 9 9 9 9 9 9 9 9 999 9 99 99 9 9999 99999 99 99 99 9 • 9 999 9999 ·· · ·· 99 9 99 99 stop and use a J-shaped back to mount metal strips to secure the component to the wooden posts.

SUMMARY OF THE INVENTION

The present invention relates to a door frame that is much cheaper than existing door frames, shows all the benefits of solid wood frames in terms of workability and insulation, but is stronger, impermeable and insect resistant and will not fray, break, collapse , rust or rust, and will not require the maintenance required for wooden frames.

According to the present invention, the door frame is formed from components of a composite molded material which is molded into precision profiles ready for quick, easy and accurate assembly.

More specifically, according to the present invention, the frame components are moldings of filler, waste or recycled particles or small pieces (hereinafter referred to as particulate material) joined together by a thermoplastic material, which may be a waste or recycled thermoplastic.

Such molded components according to a preferred embodiment of the present invention are formed to provide intermeshing positioning means to ensure that they are brought together in very accurate alignment, ready to be secured by suitable fastening means.

In this context, it should be noted that by ensuring accurate engagement of the components of the assembly, a minimum number of fasteners is required to secure the elements.

of the frame in the assembled state, which allows the door frame to be assembled and assembled quickly, easily and accurately.

By being molded, the present invention allows the pillar and upper frame members to be formed as δ

elongate channels or boxes suitably reinforced therein which present stepped bottom surfaces to be directed to the inside of the opening receiving the door to be framed by the door frame. Such actually hollow outer frame members therefore require a minimum of material-forming

Ω lightweight elements for easy handling and installation.

In addition, by molding the frame members, these members may be formed to provide integral drilled brackets, protrusions, or reinforced areas for receiving, supporting and positioning passing bolts or the like therethrough so that the frame members may be secured to the door frame opening.

Moreover, by providing the door frame elements by a press or the like operation, an accurate positioning can be ensured

2Q the mounting areas for the hinge and latch plate and forming suitably positioned internal reinforcing hollow brackets or material blocks to receive the latch and plug accessory insert.

According to the present invention, the pillar and top members of the frame may also be molded to form very accurate integral moldings conforming to brickwork (sometimes refined to a brick molding) when the door frame is intended for an exterior door.

Where it is desired to use a separate brick molding in accordance with the present invention, an elongate brick is formed. 9 9 9 9 A molded channel element with bevelled ends and transverse ribs, including ribs extending obliquely between the walls of the channel; and ribs extending perpendicularly between the walls of the channel, the molding may be cut at appropriate locations to form bevelled top moldings, the moldings having varying lengths depending on the width of the door, and pillar moldings having bevelled upper ends for either left or right door pillar.

According to the present invention, where desired, the door frame sill is further formed as a molded composite structure with a repeating inner pattern so that it can be cut at appropriate locations to suit the width of the door to be received by the door frame.

The foregoing and other features of the present invention will become more apparent from the following detailed description of exemplary embodiments thereof with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a perspective view illustrating a molded door frame for a pendulum door with a separate alignment or brick molding according to the present invention;

Fig. 2 is an enlarged perspective view illustrating the connection of the top of one of the frame posts of Fig. 1 to the top (lintel);

Giant. 3 is a perspective view illustrating how the bottom of one of the posts is coupled to the threshold and showing the alignment post or FIG. · Brick molding in a position intended for engagement with a frame post; · · cih cih cih cih cih cih cih poloze poloze poloze poloze poloze

Giant. 4 is a view similar to FIG. 3 but illustrating an exterior swing door;

Giant. 5 shows a vertical section through a door frame with a separate alignment or brick molding attached;

Giant. 6 shows a perspective view of a molded -QQ threshold according to the present invention, which can be cut to suit different dimensions of the frame to accommodate different door widths;

Giant. 7 is a perspective view of an elongated molded structure from which columns and top cleans of a separate alignment or brick molding for a door frame can be formed;

Fig. 7a shows a side view of the lower molding of Fig. 7 which has been placed on its side;

Giant. 8 is a perspective view of one of the door frame posts illustrating how the post is secured to a door receiving opening in a building wall;

Giant. 9 shows a detail in a horizontal section of the post and wall structure of FIG. 8, illustrating a door in place which displaces the flexible flexible sealing strip used to cover the fastening screws when they are.

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99

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99 shows the door open, only one screw being illustrated;

Fig. 10 is a view similar to Fig. 9, but with the door open, illustrating the flexible flexible sealing strip as it now covers and hides the fastening screw;

Fig. 11 is a perspective view of a section of a door pillar to which a door is to be hinged, illustrating one of the recessed receiving hinges;

Fig. 12 is a rear perspective view of the post shown in Fig. 11 illustrating an arrangement of integral brackets or protrusions formed with through-holes or bores for receiving bolts to secure the hinge to the door post;

Fig. 13 is a perspective view of a post to receive a latch plate for a door and which includes a latch recess and a door locking plug;

Fig. 14 is a rear perspective view of the post of Fig. 13 illustrating molded reinforcing material blocks or brackets for receiving a latch mechanism and a door latch;

Fig. 15 shows a front view of a door frame according to the present invention in which the alignment or brick molding is molded

4 4 ♦♦ 4 4 4 4 4 4 4 4 · 4 4 4 4 4 4 4

9 4 44 4 4 · · 4 444 44 44 4 4 4 4 4

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44444 94 · 44 44 integral with the pillars and with the upper part of the door frame;

Fig. 16 is a perspective view of the door frame of Fig. 15, ready to be placed in the c opening of the door in the wall;

Fig. 17 is a perspective view illustrating an upper alignment assembly with an integral alignment or brick molding with pillar tops having an integral alignment or brick molding;

Fig. 18 is an enlarged perspective view illustrating a connection between one of the posts illustrated in Fig. 17 and one end of the mating top;

Fig. 19 is a perspective view illustrating a method of joining the bottom of the left post to the threshold for an inwardly opening swing door;

Fig. 20 illustrates a right post to be attached to the other end of the sill;

Fig. 21 is a horizontal cross-sectional view illustrating a door frame with its integral alignment or brick molding mounted in a door receiving opening with the door in the closed position;

Fig. 22 is a vertical sectional view showing the door frame assembly of Fig. 21;

· * * ΦΦΦΦ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ φ

Fig. 23 is a perspective view illustrating a door frame and a side light frame ready for attachment with a separate alignment or brick molding;

Fig. 24 is a front view illustrating a door frame and a separate side light frame assembled with a fixed perimeter molding.

DETAILED DESCRIPTION OF THE INVENTION

In general, FIG. 1 shows a door frame X which comprises a left-hand post 2, a right-hand post 2 / an upper part 4. (lintel) and a threshold 5.

Also shown in FIG. 1 is a separate alignment or brick molding for attachment to the door frame X, which includes a left molding column 6, a right molding column 7, and a molding upper portion 8. As shown in FIG.

Each of the pillars 2 and 3, the upper part 4 and the threshold 5 of the door frame 1 is formed of a synthetic material comprising a molding of filler, waste or recycled particulate material. bonded together by a thermoplastic binder, which is preferably a waste or recycled thermoplastic. Similarly, each of the forming columns 6, 7 and the forming portion X is also a molded part of a similar synthetic material.

The particulate material to be used in the door frame elements is selected to provide desirable properties such as temperature stability, strength, and hardness.

Where the door frame is to be exposed to significant temperature changes Particulate filler, waste or recycled material · «9 ··· • 99 * 999 9 9 • · 9 9 9

9 * 9 9 9 9

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9 99

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99 99 preferably comprises at least a portion of the fibrous material, such as wood flour, sawdust, shredded / or ground waste fabric or paper. The thermoplastic binder material may include, for example, recycled PVC or polyethylene, and the weight ratio should preferably be about 30% to about 60% to 70% of the particulate material with up to 100% of the thermoplastic binder material or, in principle, thermoplastic binder material together, this is desirable with some particulate additive such as fly ash or brick dust to impart hardness and strength. For example, since amounts of sawdust are usually readily available, in particular the conventional compound material for outer door frames exposed to large temperature ranges comprises approximately 50% sawdust and 50% recycled polyethylene. However, it should be understood that the percentage and nature of the filler, waste or recycled particulate material and thermoplastic material can vary widely depending on the requirements of the door frame, and there may be some cases in which the ratio of particulate material to thermoplastic material may be up to 90% to 10% and vice versa.

With respect to the thermoplastic material, the recycled polyethylene may be re-milled low, medium or high density polyethylene. Other examples of useful o-recycled thermoplastics include re-milled polypropylene, polyethylene terephthalate (PET), nylon, and ABS.

Other examples of filler, waste or recycled particulate materials to be joined together by a thermoplastic binder may include, but are not limited to, for example, 99 99

9 9 9 9

9 9 9 9 9 9 9 9 9 «999 99 99

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999 99 99 9 99 99 glass fibers or particles, re-milled thermosetting materials, milled shells such as peanuts, and husks such as rice or corn husks, milled rubber or metal particles and other hard materials.

When molding the door frame components, preferably the particulate filler, waste or recycled material and the recycled plastic material are fed into the mold as a well-mixed mixture of hot particulate material having its particles coated with the molten thermoplastic material, then encapsulating the molten thermoplastic material. joins the coated particles into a solid densified bonded mat.

Each of the posts 2 and 3 and the upper parts are molded into an elongated box construction. The posts have elongated side walls 9 and end walls 10, and the upper portion 8 has elongated side walls 11 and end walls 12.

Standard doors are 79 inches (about 200.7 cm) tall and typically have widths ranging from 30 inches to 42 inches (about 76.2 to 106.7 cm), with most doors having a width of either 32 inches or 36 inches (approximately 81.3 or 91.4 cm).

However, it should be understood that the door heights may vary, for example, some doors are 96 inches tall (about 243.8 cm), and the width of the double doors will, of course, be substantially greater than 42 inches (about 106.7 cm).

As a result, it will be appreciated that the posts 2 and 3 must have a length to receive the door height, while the length of the upper portion 4 will vary to accommodate different door widths.

As shown in Fig. 2, Fig. 3 and Fig. 4, the box structures of each of the posts 2 and 3 are formed.

* · * * 9 9 9 9 9 9 9 · · · · 9 9 9 9 9

999 99 99 99 9 9 9 9 9 9 9 with a stepped base to be directed towards the inside of the door receiving opening to be framed by the door frame and the bottom including a first step 13 presenting a first longitudinally extending outer lower planar surface 13a of width for receiving a door edge thickness, such as the door 14 shown in Fig. 5, to be mounted in the frame.

On the side of this first step 13, a second step 15 presenting a second longitudinally extending lower planar surface 15a extends inward beyond its planar surface 13a. The transition between steps 13 and 15 defines a stepped door stop 16.

The interior of each of said posts 2 and 3 is divided in the middle of its width in a line with a transition between the first and second stages 13 and 15 extending longitudinally through the wall 17 which actually divides the interior of the posts into two adjacent channels 17a and 17b, the channel 17a being shallower than 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 posts. The arrangement is such that when the posts 2 or 3 are mounted in a wall opening of the building, as illustrated in Fig. 4, the edges 18 and 19 will abut the frame of the building wall opening, consisting for example of two frame members 20 and four rungs 21 walls.

The stepped bottom of each of the posts 2 and 3 is formed with a groove 22 in transition between steps 13 and 15. The groove 22 extends into the longitudinally extending wall 17 and is adapted to mount a flexible flexible sealing tape 23 for purposes that will be described in more detail in the description below.

The inwardly projecting second step 15 of the posts 30 is shown to terminate shortly before the end walls 10.

• · · · ·

pillar. As illustrated in particular in FIG. 2, the upper end of step 15 ends with a flat projection 24 which is adapted to form a positioning seat for the upper portion 4, as will be described in more detail below.

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Similarly, the lower end of the step 15 ends shortly before the lower end of the post with a slightly oblique protrusion 25 adapted to sit on the threshold 5, as will be described in more detail below.

As shown in FIG. 5, it has a molded upper portion

4, similar to the posts 2 and 3, preferably a stepped bottom surface which, when the top part 4 is installed, faces the inside of the door frame aperture, wherein the stepped bottom of the top part comprises a first step 26 presenting a longitudinally extending outer bottom planar surface 26a for receiving the edge of the door to be mounted in the door frame and a second step 27 presenting a longitudinally extending outer lower planar surface 27a, the second step 27 extending inwardly beyond the surface 26a to form a stepped door stop 28 as shown in FIG. 5.

The longitudinal wall 29 in alignment with the transition between steps 26 and 27 divides the interior of the upper portion in the middle of its width into a pair of adjacent channels 30 and 31, the channel 30 being shallower than the channel 31.

It should 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 upper portion for mounting in the opening receiving the door frame in the wall into which the door frame and door are to be mounted as illustrated in FIG. 4.

In the illustrated arrangement, particularly as illustrated in Fig. 2, the lengths of the upper steps 26 and 27 and the upper channels 30 and 31 are the same so that the end wall 12 at each end of the upper portion will contact the front region 34 of the respective post above the flat a column protrusion 24 with a lower surface 27a of the upper portion 27a resting on the protrusion 24.

As illustrated in Fig. 2, the end wall 12 of the upper portion is formed with generally semi-circular notches 35 spaced, while the post 3 is shown with integral pins or protrusions 36 that engage the notches 35 to provide a properly aligned assembly between the upper and a post with an upper portion seated on a post 24 of the post.

The interior of the top wall 12 of the upper portion is formed with 15 integral projections 37 to provide a body of material having a receiving depth and provide adequate holding force for the bolts 38 that extend through the column and into the face of the upper portion and into the projections 37 when assembling the upper portion with the column .

The upper portion may be cut transversely to match different door widths or for use in side light frames, as will be explained in the description below, by providing one or more inner transverse walls 12 as shown in FIG. 2, which are formed with notches 35 '. , corresponding notches 35, and projections 37 ', corresponding projections 37.

It will be appreciated that the arrangement at one end of the top portion, as illustrated in Figure 2, will be repeated at the other end to assemble the top portion with the posts.

As shown in Fig. 1, the interior of the post 2 is formed with internal integral protrusions 39 extending from the inner surface of the bottom wall to provide support for the bolts 38 to assemble the post and the top. Preferably, the projections 39 are formed with passages or bores 39a extending therethrough, these bores 39a being shown as extending from the wall portion 40 above the projections 24 of the right pillar 3 in Fig. 2, it being understood that the right and left pillar they are absolutely identical with respect to the alignment and fastening arrangement with the upper part.

The posts 2 and 3 are preferably formed with transverse stiffening ribs 41 extending between the longitudinal middle wall 17 and the side walls 9 of the posts.

Similar ribs 42 are formed in the upper portion 4, which ribs 42 extend between the middle longitudinal wall 29 of the upper portion and the side walls 11 of the upper portion.

As in the case of the posts, the stepped lower surface of the upper portion 4 is formed with a groove 43 in the transition between steps 26 and 27, which groove extends all the way to the middle wall 29 for mounting the flexible flexible sealing tape 23.

By creating a bore through the projections 39 with a diameter such that they receive the bolts 38 in a shear fit, the posts can be secured to the top without unscrewing the screws back from the posts from the ends of the top.

The threshold 5 shown in Fig. 3, Fig. 3, Fig. 5, and in particular Fig. 6, like the columns 2 and 3 and the upper part 4, is formed by molding a composite material comprising a filler, waste or recycled. the particulate material and the thermoplastic binder as mentioned above.

As shown in FIG. 6, the threshold 5 is preferably formed as an elongate element to cover the entire range of door widths or dimensions, and is adapted to cut at various locations corresponding to the width of the door to be received by the door frame.

As shown in FIG. 6, in its elongated form, the top of the threshold 5 comprises a narrow horizontal portion 44 extending over the longer threshold and a wider slanted portion 45 separated by a longitudinal groove 46.

Between the end walls 47 and 47a, the outer walls or legs 48 and 49 and the middle legs 50 and 51 are spaced, all of which legs coincide with the lower edges of the end walls 47 and 47a.

The end walls 47 and 47a are formed with notches 53 for receiving correspondingly shaped pins or projections 54 formed at the bottom of the posts 2 and 3, as illustrated in Figure 3.

On the inside of the end walls 47 and 47a, integral inwardly projecting protrusions 55 are provided to provide depth of material to engage and to provide retaining forces for the fasteners or screws 56 used to assemble the sill posts as illustrated in Fig. 3.

By providing protrusions 54 on the posts and notches 53 in the end walls 47 and 47a of the threshold, precise alignment between the posts and the threshold can be achieved before locking these elements together.

♦ ♦

As illustrated in FIG. 1, the posts 2 and 3 are also provided with inner protrusions 57 to provide support for the fastening means 56, these protrusions are again formed with the bores 57a for shearly mounting the fastening means 56 so that when screws are used their rotation does not pull them from the lower end of the posts as the bolts penetrate the material of the sill protrusions 55.

As illustrated in Fig. 6, the end walls 47 and 47a are substantially doubled at locations along the length of the threshold element shown in Fig. 6 to create thresholds of different door widths or a threshold for a door with a side light frame, as will be explained in more detail in the description. below. Cutting threshold of FIG. 6 outside of walls 58a, 58b and 58c are formed by end walls 47 _ir 47 ₂ and 47 ₃ complete with notches 53 and flanges 55.

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Similarly, if the elongated threshold of FIG. 6 is cut outside the walls 59a and 59b, the right end wall 47a will be double as the end walls 473 ₂ and 47a ₂ completely with the notches 53 and the protrusions 55.

In installation, the threshold 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, which are arranged to engage with each other in the longitudinal groove 46.

The additional protective aluminum extrusion 62 is arranged to lock together with either the aluminum extrusion 60 at the inwardly opening swing door or the vinyl extrusion 61 at the outwardly opening swing door.

When assembling the door posts 2 and 3 to the ends of the upper parts 4, only two screws are required for each

0 post to pass through .39 post drill bits and into

• · · · · · ·

projection. 37 upper part. Similarly, only two screws for each post are needed to secure the post to the threshold 5, which screws pass through the bore studs 57 of the post and into the thresholds 55. Thus, the entire door frame can be assembled with only eight screws.

As regards the attachment of the pillars 2 and 3 of the assembled door frame to the opening in the wall for receiving the door frame, this is shown with reference to Figs. 8, 9 and 10. As illustrated in Fig. 8, inwards the facing lower planar surface 13a of the column step 13 is provided with recesses in selected areas 63 at intervals along its length. As shown in Figs. 9 and 10, the interior of the post beyond the selected region 63 has a massive post 64 of material extending at depths of step 13. This massive post 64 is formed with a bore 65 extending therethrough with a diameter for shear mounting of the fasteners. means or bolts 66 such that when mounting the post against the bore frame member 20 receiving the door frame, the rotation of the bolt 66 to penetrate the post clamping frame member 20 to the frame member will not act to pull off the post.

Giant. 9 illustrates a mounted post with a door 14 in a closed position that compresses a flexible flexible sealing strip 23, thus revealing a head of a bolt 66 that is seated in a selected area 63. However, the head of this bolt will not be visible with the door 14 in a closed position.

Giant. 10 is a view similar to FIG. 9, but without the door 14, illustrating a loosened flexible flexible sealing strip that is thus stretched over the bolt 66 and conceals the bolt when the door is open.

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ΦΦ · ·

It will be appreciated that when the door 14 is assembled, the door 14 will be hung on one of the posts 2 or 3, and the other post will receive a latch plate of the latch and plug arrangement of the doors where required.

Giant. 11 and 12 illustrate, as an example, a pillar 3 to which a door is to be hung.

As shown in FIG. 11, the inwardly facing lower planar surface 13a of step 13 is provided with a recess 68 for embedding one hinge wing shown in FIG. 12.

On the opposite side of the post beyond the area provided with the recess 68, the interior of the post is formed with a series of integral interconnected posts or projections 70 extending through the depth of step 18 to provide a material body for

15 receiving screws or hinge fasteners 71.

The planar surface 13a of the opposite post, i.e. the post 2 _r, is shown in Fig. 13 as having a recess 72 for receiving a latch plate, not shown, and also provided with a recess 73 for receiving a plug plate, also not shown.

Downstream of the ratchet recess 72 in the interior of step 13 is an integral material block 74 passing through the depth of step 13. The ratchet recess 72 is formed with a rectangular bore 75 extending into the block 7 4 25 to secure the door ratchet opening.

Similarly, behind the recess 73 for the plug is a material block 74 ', wherein the region of the recess 73 for the plug is formed with a rectangular bore 76 extending through the integral block 74 / material to receive the door locking plug.

• * ΦΦΦ 1 1 1 1 1 1 1 1 1 1 1

Φ Φ Φ

It will be appreciated that when viewing the pendulum doors opening inwardly as shown in FIG. 1 from outside the building, it will be the right-hand pillar 3 that will be designed to receive the hinges, typically using three hinges. The left post will be designed to receive the door latch and the door plug where it is used. However, it should also be understood that the opening of the door can be reversed, in which case the left post will receive the hinges and the right post will receive the latch and the door plug.

The roles of the pillars will be reversed in the case of an outward opening swing door.

For forming the door frame X of Fig. 1, a molding element is formed comprising the molding columns 6, 7 and the molding top 8. As mentioned above, the molding element is formed as a molded composite material as described above. Since the molding elements 6, 6, X do not support the loading of the door, it is clear that the nature of the particulate material and the percentage of particulate material and thermoplastic material may vary from what was used in the formation of the door frame itself.

These molding elements 6, 7 and 8 can of course be individually molded or can advantageously be obtained by suitably cutting the elongate molding channel 78 shown in FIG. 7. This channel 79 is formed with bevelled ends 80, rows of oblique inner ribs 81 and perpendicular ribs 82 extending between the channel side walls 83. By cutting along the appropriate lines 84 coinciding with the inclined inner ribs 81, the correct lengths of the molding upper portion X can be obtained to accommodate the dimension of the door frame required for the dimension. Of the selected door or, if a side door frame is used, of the correct length needed to frame the top of the door and the side door frame. It will be appreciated that the cutting will proceed in such a way that both ends of the molding top are tapered.

By cutting the molding element or channel 79 transversely at right angles to said side walls 82, door molding columns 6 and 7 can be formed.

When the molding part 8 and the molding posts 6, and 7 are fixed to the door frame 1, such as by means of square nails, these frame elements will form the upper corners cut to miter.

Although preferably the posts 2 and 3 are formed such that the stepped door stops 16 presented by the second stages 15 are shorter than the door edge receiving surfaces 13a presented by the first stages 13, to form the mounting lugs 24, as shown in FIG. 2, and the stepped door stop 28, represented by the second step 27 of the upper portion 4, extends over the entire length of the upper portion 4, this relationship may be reversed if desired. That is, the second step 27 of the upper portion and thus the stepped door stop 28 may be formed terminating shortly before both ends of the first step 26 of the upper part, while the stepped door stops 16 on the posts may continue to the tops of the posts.

It should be understood that in the case of interior doors where thresholds are not required, the posts will go down so that they rest on the floor. .

Giant. 15 to 18 illustrate a door frame 85 having pillars 86 and 87 and an upper part 88 (lintel) which are identical.

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99 • 9 9 9 • 9 99 with the columns 2, 3 and the upper part 4, except that they have integrally molded molding elements corresponding thereto to the forming columns 6 and 7 and the forming upper part 8. Because in all other respects the columns 86 and 87 and the upper part 88 correspond to columns 2 and 3 and the upper part 4, the same parts are designated with the same reference numerals. Threshold 5 remains unchanged.

Giant. 15 shows a door frame 85 with pillars with their integral molding portions 89, a top portion with its integral molding portion 90 and a threshold 5 assembled in a ready state for placement in a frame receiving opening in the wall. Giant. 16 illustrates an assembled door frame 85 around which frame members 20 of an opening in a wall are to be mounted to be mounted therein.

As shown in FIGS. 17 and 18, and in particular in FIG. 22, the integral molding portion 90 of the upper portion in the case of inwardly opening swing doors, which represent a major portion of the market, extends outwardly from the side wall 11 of the upper portion in 22. The upper mold portion 90 is actually an elongated L-shaped section having a shorter portion 91 extending outwardly perpendicular to the upper wall 11 at a point retracted from the planar portion. a surface 27a and a longer portion 92 extending perpendicular to the shorter portion 91 and forming a front wall of the mold portion of the upper portion that extends outwardly from the aperture defined by the door frame, as shown in Figure 22.

As shown in FIGS. 17 and 18, the ends of the upper mold forming portion 90 are closed by an inclined wall 93 and a short return wall 94 to form bevelled mounting surfaces to engage the post forming elements 89 for

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999 99 ·· 9999

99 • * 9

9 9

99 to form miter cut corners when the upper portion 88 is assembled with the columns 86 and 87 as described below.

As shown in particular in FIG. 21, as in the case of the mold portion 90 of the upper portion, each of the mold portions c is:

The pillars have an elongated generally L-shaped structure having a shorter portion 95 extending outwardly perpendicular to the pillar wall 9 at a point retracted from the planar pillar surfaces 15a and a longer portion 96 extending outwardly from the aperture defined by the door frame.

Giant. 21 illustrates the function of integral pillar forming portions 89 that not only provide a balanced appearance with the door frame, but protrude to interfere with the masonry 97 (and hence the brick moldings) to which they are sealed by a gasket 98 to create an air space ¹⁵ between the masonry building structure formed by the frame elements 20 and the wall partitions 21 to provide an insulating effect.

It will be appreciated that a similar function will be provided by the upper portion forming portion 90.

As shown in FIG. 17 and FIG. 18, the upper ends of the posts forming parts 89 are closed by a sloping wall 100 and a short return wall 101. The bottoms of molding the portions of the posts 8 9 are provided with inturned feet 102 as _e j shown in Figure 19.

The assembly of the columns 86 and 87 with their integrally molded molding parts 89 with the threshold 5 is identical to that described in connection with the columns 2 and 3 and the threshold 5 as illustrated in Figs. 18 and 20.

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9 99 **

In many cases, installing a door frame may require the formation of a side light frame on one side or even on both sides. Giant. 23 and 24 illustrate an installation comprising a side light frame 103 to be fixed to the door frame i. It will be appreciated that this side light frame 103 is adapted to receive a conventional double-pane window pane (not shown) that it has a thickness corresponding to the thickness of the door in the same way as the door frame is adapted to receive the door. The side light frame 103 is formed of posts 104, a top 105 (lintel) and a threshold 106, which correspond to the posts 2 and 3 and the top 4 and the threshold 5, respectively, except that the posts do not have means for hinge mounting; receiving the door accessories and the inner bracket associated with this accessory, but as will be appreciated have suitable inner brackets (not shown) for assembly with the door frame 1 and for mounting in the wall opening in which the frame is to be received. The upper portion 105 is formed by cutting an upper portion corresponding to the upper portion 4 in suitable inner walls 12 '. (see Fig. 2) according to the width of the side light frame. The threshold 106 is formed by cutting a threshold corresponding to the threshold 5 of FIG. 6 in a suitable inner wall, for example wall 47a, according to the width of the side light frame.

After the frames 1 and 103 are secured together in an adjacent relationship, these joined frames are given an integrated appearance by adding an aluminum profile member 107 corresponding to the protective aluminum molding 62 shown in Figure 20 that extends along the length of the joined frames. To receive this continuous profile member 107 extending over the joined frames, the front edges of the adjacent undersides of these frames are provided with notches 108 and 109, respectively.

99 • 999 · 9

9 * 9 9

989 99 9

9 9 9

999 99 99

9 ···

99

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9

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It will be appreciated that, if desired, the thresholds 5 and 106 could also be formed as a continuous component with suitable indentations at the rear edges of the undersides of adjacent frame pillars.

After assembling the frames 1 and 103, a separate frame molding portion 110 is then applied with the molding top portion 111 and the molding columns 112 cut from the elongated molding shown in Figures 7 and 7a at appropriate lengths.

It should be understood that the door frame assembly, if desired, also includes a frame of, for example, a small door using the upper portion 4 and short posts having a basic structure such as the posts 2 and 3.

Although preferred embodiments of frame 25 molded from composite material and component components of the present invention have been described, it should be understood that various changes in the structural details of these frames and components can be made and that these elements can be molded from a wide range of composite materials comprising particulate materials joined together by a thermoplastic binder, without exceeding the scope of the appended claims.

Claims (15)

The engaging alignment formations (35, 36) for aligning these elements in the correct relative position prepared to secure them together. 00 · 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PATENT CLAIMS A door frame assembly comprising a pair of molded posts (2, 3) and a molded top (4) that are molded of a mixed material, wherein each of said posts and the top is formed to present first and second adjacent parallel longitudinal open channels (17a, 30, 17b, 31) having spaced side walls (9, 11) and a common central wall (17, 29) respectively, whose edges (18, 32) lie in the same plane as the edges (19, 33) the columns, respectively, the upper portions, said channels being closed at their ends (10, 12), said second channels (17b, 31) presenting bottoms (15a, 27a) extending beyond the bottoms (13a, 26a) of said first channels (17a, 30) and parallel thereto such that when assembling said top portion and columns, the bottoms of said first channels define an opening receiving a door, said bottoms of said first channels The columns are adapted to mount door accessories and the undersides of said second channels (17a, 31) extend inwardly from said opening receiving the door, said first and second channels forming a door stop assembly (76). 2 of said first channel has an arrangement of integral inner material blocks (74, 74) against said recesses for receiving fastening means for fastening said latch plate and door plug accessories. A post according to any one of claims 12 to 21, 30, wherein said blend material comprises · · φ · ♦ · Φ · Φ · φφφ Pl φ φ φ φ φ φ φ pl filler, waste or recycled particulate material bonded together by a thermoplastic binder. The door post of claim 22, wherein said thermoplastic binder is recycled thermoplastic. 24. A molded composite door frame top (4) characterized in that it is configured to present first and second adjacent parallel longitudinal open channels (30, 31) having spaced side walls (11) and a common central wall (4). 29), the edge of which is in the same plane as the edges (33) of the side walls (11), said channels being closed at their ends (12), said second channel presenting a bottom (27a) extending beyond said bottom (20a) a first channel and in parallel thereto, said first and second channels forming a stepped door stop (28). Upper part according to claim 24, characterized in that said common central wall (29) has a groove (43) for receiving a sealing strip open to the bottom of said channels. The upper portion of claim 24 or 25, further comprising an alignment molding portion (90) formed integrally with the outer wall of the first channel (30). An upper portion according to claim 24, 25 or 26, wherein said composite material comprises a filler, waste or recycled particulate material bonded together by a thermoplastic binder. 28. The upper portion of claim 27 wherein said thermoplastic binder is recycled thermoplastic. · T t t * * * t t t t t t t t t t t t t t t t t t t t t t t t t t · · · · · · · · · A molded structure (79), characterized in that it is a molding from which frame molding portions comprising a pair of posts and an upper portion joining said posts can be cut to receive different frame widths, wherein: Door frame assembly according to claim 1, characterized in that the bottoms presented by said second channels of said columns, which extend beyond the bottoms of said first channels, terminate shortly before the upper ends of said columns and form support lugs (24) for said upper portion. The door frame assembly of claim 1 or 2, further comprising a molded threshold (5). Door frame assembly according to claim 3, characterized in that the bottoms presented by said second channels of said columns, which extend beyond the bottoms of said first channels, terminate shortly before the lower ends of said columns and form projections (25) for seating said columns on said threshold . 5, said molding structure comprises an elongated molded channel formed from particulate material joined together by a thermoplastic binder, said molding structure having longitudinally extending side walls (83) and closed tapered ends (80) with a chamfer at one end opposite to the chamfer on 5 a bottom (13a) of said first channel and parallel thereto, said bottom channels of said first channel being adapted to mount door accessories, said first and second channels forming a stepped door stop (16). Door frame assembly according to any one of the preceding claims, characterized in that said common central wall (17, 29) of said channels of said posts and of the upper part is formed with a groove (22, 43) receiving a sealing strip which is open to the bottom of said channels. Door frame assembly according to any one of the preceding claims, characterized in that each of said uprights and upper portion is formed with an integral molding portion (89, 90) at one face thereof, presented as an outer frame face when assembled, to define a door receiving aperture, each said integral portion including an L-shaped component having a short transverse portion (95, 91) extending perpendicular to its respective outer frame face at a location offset outside of said door receiving aperture and a longer outside passing portion (96) 92) extending outwardly at said door receiving opening and perpendicular to said short portion. A door frame assembly according to any one of the preceding claims, wherein said pillars and upper portions are molded to form one another 0 0 · 0 0 0 0 0 0 0 0 0 0 0 0 · 0 00 • 0 0000 Door frame assembly according to any one of the preceding claims, characterized in that the interior of at least said first channel (17a, 30) of each of said posts and top is formed with an arrangement of integral thickened regions (70, 37) adapted to receive and support. fastening means introduced through these regions. 9 9 9 9 9 9 9 9 9 9 • ΦΦ · · · Φ · Φ φφφφ «ΦΦΦ The means (36) for aligning with the upper portion adjacent to its top and means (54) for aligning with the threshold adjacent to its bottom. A post according to any one of claims 12 to 17, characterized in that it has an L-shaped forming part (89) integrally formed therewith. A post according to any one of claims 12 to 18, wherein the interior of at least said first 20 of the channel (17a) is formed with an arrangement of integral thickened regions (70) adapted to receive and support fastening means introduced therethrough. A post (3) according to any one of claims 12 to 18, wherein the bottom (15a) of said first channel ¹⁵ (17a) is formed with recesses (63) for receiving the hinges and the interior of said first channel opposite said recesses for receiving the hinges is formed with a pattern of integral inner brackets (70) for receiving fastening means for securing hinges received in said recesses. A post (12) according to any one of claims 12 to 18, characterized in that the bottom (13a) of said first channel (17a) is formed with recesses (75, 76) for receiving the latch plate and the door accessory and the interior of the door. Door frame assembly according to any one of claims 1 to 8, characterized in that said first channels of said columns and upper portions are formed with inner brackets (64) adjacent to their common walls, said brackets having through through openings (65) for passing the fastening means therethrough to secure said posts and top to the opening receiving the door frame. 9 99-9 of a mixed material having a longitudinal channel shape closed at the ends (47, 47a). 9 9 9 9 99 9 9 9 9 9 9 9 999 99 ·· · ♦ «9 · · 9 9 * 9 9 9 9 • 9 9 9 9 In the other end, said duct has between the side walls extending rows of inclined transverse walls (81) and rows of perpendicular transverse walls (82), the arrangement of which is such that when forming said channel in a selected one of said inclined transverse walls parts A door frame assembly according to any one of the preceding claims, wherein said composite material comprises a filler, waste or recycled particulate material bonded together by a thermoplastic binder. The door frame assembly of claim 10, wherein said thermoplastic binder is recycled thermoplastic. A molded column (2, 3) molded from a composite material, characterized in that it is designed to present first and second adjacent parallel longitudinal open channels (17a, 17b) having spaced side walls (9) and • ·· • * ·· • • ·· • • • »·« · • • ··· · • • * • · • • • · • • · • • • • ·· · ·· ·· • ·· ·· a common central wall (17) whose edge (18) is in the same plane as the edges (19) of said walls (9), said channels being closed at their ends (10), said second channels presenting a bottom (15a) extending beyond A post according to claim 12, characterized in that the present bottom (15a) of said second channel which extends beyond the bottom (13a) of said first channel ends shortly before the top of said post to form a support projection (24). 15 Dec A post according to claim 12 or 13, characterized in that the present bottom (15a) of said second channel extending beyond the bottom (13a) of said first channel ends shortly before the bottom of said post to form a settling projection (25). A post according to any one of claims 12, 13 or 14, characterized in that said common central wall (18) has a sealing strip groove (22) open to the undersides of said channels. A post according to any one of claims 12 to 15, wherein the bottom of said first channel has a plurality of recesses (63) for receiving screw heads adjacent to said stepped door stop (16). A post according to any one of claims 12 to 16, 30, characterized in that said post is formed with 9999 99 · Φ 98 9 9 9 9 9 9 9 9 9 15 of the upper portion for different frame widths, while by cutting said channel in a selected one of said perpendicular transverse walls, column molding portions with tapered upper ends may be formed selected for attachment to the left or right column of the door frame.