Abstract:
A portable doorframe installation jig is disclosed, adapted to allow a construction worker to readily install a new doorframe plum, level, and in plane. It also may be used as a brace to retain doorframe position during installation of framing and/or drywall. It may also be used as a reinspection tool after installation of drywall. The door jig further serves the purpose of stabilizing the doorframe, in some embodiments, during construction.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to construction tools, and more particularly relates to a jig for installing properly dimensioned doorframes and for maintaining the integrity of a doorframe during construction of fixtures proximate to the doorframe. 
     2. Description of the Related Art 
     Doorframes and door jambs are well-known in the art. Typically, in most residential and commercial settings, doorframes, for mounting hinged doors, comprise wooden frames or hollow metal frames including the following principal components: a head jamb (constituting a horizontal member above the recess and below the lintel); jambs (constituting vertical members laterally defining the recess meant to house the door), and a sill (constituting a horizontal member below the recess designed to house the door). The head jamb, jambs, and sill may rest on or above concrete, metal, and/or wood structural components of a wall, building, bulkhead, etc. 
     Typically, in residential and commercial construction projects, doorframes are created with stamped light gauge metal components of various widths (or other wooden components well known to those of skill in the art) during the framing phase in construction, which precedes the finishing phase. The wooden components are affixed together using nails, screws, gusset plates  111 , and the like, while the metal components may be welded, screwed or bolted. 
     While construction workers are careful during framing to define door recesses of exact dimensions called for by plans, blue prints, and the like, the framing is never completely rigid or stable until construction is finished. As the framing phase progresses, some framing components are strained through tensile and/or compressive forces, which often alter the dimensions of, squareness, and/or parallelism of, the jambs or other components in the walls including the doorframe. 
     The doorframe installation process can be tedious. Components must be precisely measured and assembled, and there exists no efficient guides in the art for use in installing doorframes. 
     Even when the finishing phase is in progress, drywall (i.e. gypsum board) being affixed to the framing components can strain framing and alter the dimensions of the doorframe, ultimately warping the doorframe such that doors created to standard or specified dimensions do not fit in the doorframe after finishing, or align properly with the frame. Doors installed in misformed frames may have non-uniform spacing between the door and the jambs. A properly installed door should touch the frame uniformly across the side of the door comprises the latch. 
     Current methods and apparatii do not readily facilitate a quick method for properly securing, stabilizing and readying a doorframe for installation. It is therefore desirable that a portable, stable tool be provided which can be used by construction crews to install a doorframe, and which can secure and stabilize a doorframe after its components are affixed together such that the doorframe remains properly in position during subsequently construction. 
     SUMMARY OF THE INVENTION 
     From the foregoing discussion, it should be apparent that a need exists for a doorframe installation tool. Beneficially, such an apparatus would overcome many of the difficulties with prior art by providing a means for properly installing and verifying newly installed doorframes. 
     The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available apparatii and methods. Accordingly, the present invention has been developed to provide a doorframe jig comprising a generally rectangular frame comprising: an elongated upper member between 0.2 meters and 5 meters in length, for abutting a head jamb, the upper member formed from a rigid substance, the upper member permanently affixed to one or more of a right lateral member and a left lateral member; an elongated lower member, for abutting a sill, between 0.2 meters and 5 meters in length, the lower member formed from a rigid substance, the lower member permanently affixed to one or more of the right lateral member and the left lateral member. 
     The jig comprises the right lateral member is for abutting a door jamb, wherein the right lateral member is permanently disposed within the frame in generally parallel orientation to the left lateral member, the right lateral member permanently affixed to the upper member at an angle of between 60 and 110 degrees, the right lateral member permanently affixed to the lower member at an angle of between 60 and 110 degrees. 
     The jig comprises the left lateral member, for abutting a door jamb, wherein the left lateral member is generally parallel orientation to the right lateral member, the left lateral member permanently affixed to the upper member at an angle of between 60 and 110 degrees, the left lateral member permanently affixed to the rear member at an angle of between 60 and 110 degrees. 
     The doorframe jig may further comprise a plurality of handles detachably affixed to one or more of the right lateral member and the left lateral member using one of bolts, screws, brackets, and welded joint(s). 
     The doorframe jig may further comprise a second generally rectangular frame hingedly affixed to the rectangular frame, the length of the second rectangular frame added to the length of the rectangular frame equally the length of standard door. 
     The jig may further comprise one or more elongated crossbeam(s), formed from a rigid substance, each crossbeam affixed at one end to a point of intersection between two or more of the upper member, the lower member, the left lateral member and the right lateral member, and affixed at an opposing end to one or more of the upper member, the lower member, the left lateral member and the right lateral member. 
     The jig further may also further comprise a girder, formed from a rigid substance, affixed at one end to the right lateral member and affixed at an opposing end to the left lateral member. 
     The members may comprise elongated, hollow metal tubes. In some embodiments, the members comprise one of bar stock, angle iron beams, pipe, I-shaped beams, H-shaped beams, tubes, and U-shaped beams. 
     Alternatively, the members may comprise a number of holes drilled through the members for securing the doorframe jig to one of clamps and braces detachably affixable to a doorframe. 
     In some embodiments, each of the right lateral member, left lateral member, lower member, and upper member are affixed with one or more gusset plate(s) to the jig. 
     The doorframe jig may further comprise a plurality of handles affixed to one or more of the right lateral member and the left lateral member. 
     A second embodiment of a doorframe jig is disclosed which comprises a generally triangular truss comprising: an elongated first crossbeam between 0.2 meters and 5 meters in length, the first crossbeam formed from a rigid substance, the first crossbeam permanently affixed at opposing ends to a lateral member and a second crossbeam; and an elongated second crossbeam, between 0.2 meters and 5 meters in length, the second crossbeam formed from a rigid substance, the second crossbeam permanently affixed to one or more of the lateral member and the first crossbeam. 
     The truss further comprises the lateral member, for abutting a door jamb, wherein the lateral member is permanently affixed to both the first crossbeam and to the second crossbeam at respective angles of between 30 and 120 degrees. 
     The second doorframe jig also comprises an elongated upper member between 0.2 meters and 5 meters in length, for abutting a head jamb, the upper member formed from a rigid substance, the upper member permanently affixed the lateral member and a second lateral member; and an elongated lower member, for abutting a sill, between 0.2 meters and 5 meters in length, the lower member formed from a rigid substance, the lower member permanently affixed to the lateral member and a second lateral member. 
     The second doorframe jig also comprises the second lateral member, for abutting a door jamb, wherein the right lateral member is oriented parallel to the lateral member, the second lateral member permanently affixed to the upper member at an angle of between 60 and 110 degrees, and the right lateral member permanently affixed to the lower member at an angle of between 60 and 110 degrees. 
     A method of installing a doorframe during construction is also disclosed, the method comprising: temporarily inserting a generally rectangular doorframe jig into the doorframe to maintain the integrity of the doorframe dimensions during installation to ensure the doorframe stays in the proper position; wherein the rectangular doorframe jig is approximately identical in dimensions of width and height to a recess defined by the doorframe, the recess for receiving a door, wherein the doorframe jig abuts all of the head jamb, sill, and door jambs; inserting the jig into the doorframe to confirm alignment of the sill, head jamb, and door jambs; removing the jig; drywalling the building; positioning the rectangular jig in the doorframe during drywalling of the building to confirm the doorframe is in the proper position and of the proper dimensions after drywalling. 
     The temporarily inserted rectangular frame may further abut a doorstop of the doorframe. The method may further comprise temporarily inserting a second generally rectangular frame into the doorframe for additional support, the rectangular frame forming part of the doorframe jig. 
     These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1A  is a side elevational perspective view a doorframe jig in accordance with the present invention; 
         FIG. 1B  is a lower elevational perspective view of another embodiment of a doorframe jig in accordance with the present invention; 
         FIG. 1C  is an upper elevational perspective view of another embodiment of a doorframe jig in accordance with the present invention; and 
         FIG. 2  is a process flow chart of a method of stabilizing a doorframe in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
       FIG. 1A  is a side elevational perspective view a doorframe jig  100  in accordance with the present invention. The doorframe jig  100  unit comprises a left lateral member  102 , a right lateral member  104 , an upper member  106 , a lower member  108 , a crossbeam  110   a , a crossbeam  110   b , a gusset plate  111 , a girder  112 , a truss  114 , a node  116   a , a node  116   b , a node  116   c , and a node  116   d.    
     In the shown embodiment, the left lateral member  102 , the right lateral member  104 , the upper lateral member  106 , and the lower member  108  are affixed, or welded to one another, at generally right angles between 80 and 100 degrees (each of the left lateral member  102 , the right lateral member  104 , the upper lateral member  106 , the lower member  108 , the crossbeams  110   a - b , and the girder  114  are collectively referred to herein after as the “members  102 - 112 ”). The members  102 - 112  may be affixed together using nails, screws, welded joints, gusset plates  111 , bolts, and the like. 
     Each of the members  102 - 112 , in the shown embodiment, comprise elongated, hollow metal tubes. Each of the members  102 - 112  may alternatively comprise rods, beams, plates, bar stock, angle, or pipe(s). Each of the members  102 - 112  may alternatively comprise cubic-shaped polymer housings. Each of the members  102 - 112  may alternatively comprise I-shaped, H-shaped, or U-shaped beams. The members  102 - 112  may comprise square- or rectangular-shaped tubing through the members&#39;  102 - 112  cross-section. The members  102 - 1126  may comprise a number of holes, bores, or apertures drilled through the members  102 - 112  for securing the doorframe jig  100  to the clamps or braces. 
     The members  102 - 112  may be manufactured from polymers, wood, metals, alloys, aluminum, magnesium, titanium, carbon-fiber, and the like. 
     The left lateral member  102 , the girder  112 , the crossbeam  110   a  and the crossbeam  110   b  collectively form the truss  114  of the doorframe jig  100 . The truss  114  is designed to withstand tensile and compressive forces imposed upon the doorframe jig  100  by the building structure as it is improved through subsequent construction. In the shown embodiment, the truss  114  is triangular rectangular from a top perspective view. In alternative embodiments, the truss  114 , from this perspective, may be circular, elliptical, triangular, polygonal, or otherwise. 
     In some embodiments, the upper member  106 , the lower member  108 , and/or the girder  112  comprise a level integrated into, above, or beneath said member, for use in leveling the doorframe jig  100  and corresponding doorframe. In some embodiments, the level is detachably affixed to one of the members  102 - 112 . In some embodiments, one or more of the members  102 - 112  comprises one or more magnets or plates for securing the level. In many embodiments, the members  102 ,  104 ,  106 ,  108  are affixed at right angles (i.e. 90 degree angles) to one another. 
     In some embodiments of the present invention, the doorframe jig  100  comprises two trusses  114 . The trusses may have opposed left lateral members  102 . The trusses may overlay one another, or may meet at a node  116  in the middle of the doorframe jig  100 . 
       FIG. 1A  shows a plurality of nodes  116 , each node  116  representing an intersection point of two or more members  102 - 112 . For instance, node  116   a  represents the intersection point of the upper member  106 , the left lateral member  102  and the crossbeam  110   a . In the shown embodiments, these said members  102 ,  106 ,  110   a  are welded together at node  116   a . Likewise, nodes  116   b ,  116   c , and  116   d  each respectively represent the intersection of various other members  102 - 112 . 
     Gusset plates  111  may overlay the nodes  116   a - d  to add additional stability to the doorframe jig  100 . The gusset plates  111  and/or members  102 ,  104 ,  106 ,  108  may be labeled with information about the doorframe jig size and dimensions. The left lateral member  102 , the right later member  104 , the upper member  106 , and the lower member  108  may each comprise one or more handles, know to those of skill in the art, for transporting and positioning the doorframe jig  100 . The handles may be permanently affixed to the doorframe jig, or detachable. 
     As construction progresses after the doorframe is constructed, the subsequent construction tends to warp, contort, or strain the doorframe, and pressure is exerted principally at the nodes  116   a - d . For this reason, the nodes  116  are reinforced with various member  102 - 112  traveling in a plurality of directions across the x- and z-axes of the doorframe jig  100 . 
     In some embodiments of the present invention, additional crossbeam(s)  110  run from the intersection of the upper member  106  and the right lateral member  104  to node  116   d  or to the midsection of the crossbeam  110   a.    
     Likewise, in some embodiments of the present invention, additional crossbeam(s)  110  run from the intersection of the lower member  108  and the right lateral member  104  to node  116   d  or to the midsection of the crossbeam  110   b.    
     The width and length of the doorframe jig  100  may be conformed to specific dimensions of standard doors, such as 36×84 inches, and the like, or to specially sized doors of non-standard dimensions. 
     In some embodiments of the present invention, the doorframe jig  100  is inserted into framing before the doorframe is constructed around it. In this manner, the doorframe jig  100  serves not only to stabilize the doorframe during finishing and after construction, but also to serve as guide during installation of the doorframe itself. 
       FIG. 1B  is a lower elevational perspective view of another embodiment of a doorframe jig  150  in accordance with the present invention. The doorframe jig  150  comprises a left lateral member  102 , a right lateral member  104 , an upper member  106 , a crossbeam  110   a , a crossbeam  110   b , a girder  112 , a turnscrew  152   a , and a turnscrew  152   b.    
     In the shown embodiment, the girder  112 , the upper member  106  and the lower member  108  are telescopic. Each can be adjusted laterally using means known to those of skill in the art to change the width of the doorframe jig  150 . In some embodiments, the doorframe jig  150  can additionally or alternatively be adjusted vertically (i.e. longitudinally) to change the length or height of the doorframe jig  150 . 
     The girder  112 , upper member  106  and lower member  108  may each comprise an inner sleeve affixed to the left lateral member  102  such that the left lateral member  102  slides out laterally away (with the inner sleeves) from the remaining body of doorframe jig  150 . 
     In some embodiments, the upper member  106 , girder  112  and lower member  108  are drilled with holes at predetermined distances for interlocking the doorframe jig  150  at different size increments using a cotter pin, r-clip, or clevis pin, and/or a hitch pin inserted through the drilled holes (for securing the inner sleeves and width of the doorframe jig  150 ). 
     The turnscrews  152   a - b , in the shown embodiment, are affixed to the base of the lower member  108 . These turnscrews  152   a - b  can be manually adjusted to raise or lower the doorframe jig  150  within the doorframe, or adjusted prior to installing or constructing the doorframe to change the height and assist in holding the doorframe level. 
     In some embodiments, the doorframe jig is designed to fold in one or more places. In those embodiments, one or more of the members  102 - 112  is divided into two “halves” which are hingedly connected together such that the entire doorframe jig  150  folds over and is more easily transportable. 
     In other embodiments, the doorframe jig  150  additionally or alternatively comprises clamps for gripping the sides of the doorframe during or after installation and/or construction. These clamps may be affixed to any of the members  102 - 112 . 
       FIG. 1C  is an upper elevational perspective view of another embodiment of a doorframe jig  180  in accordance with the present invention. The jig  180  comprises two independently manufactured sections, an upper section and a lower section, each section comprising an upper member  106 , a right lateral member  104 , a left lateral member  102 , a crossbeam, and a lower member  108 . The upper section additionally comprises two handles  182   a - b  and a hinge  184 . The corners of each section comprises nodes  116 . 
     In various embodiments, the upper section and lower section are welded or affixed together using bolts, brackets, screws, or via other means known to those of skill in the art. In some embodiments, spacers may be affixed between the upper and lower sections, permanently or detachably, to change the length of the jig  180  in assembled form. In other embodiments, the upper and lower sections are hingedly connected with one or more hinges  184  to allow the sections to fold over one another to facilitate ease of transport. 
       FIG. 2  is a process flow chart of a method  200  of stabilizing a doorframe in accordance with the present invention. 
     The method  200  begins  202  with the installation (e.g. construction)  204  of a doorframe in a residential or commercial building using means well-known to those of skill in the art, including standard wood or metal framing techniques. During the framing phase, the doorframes are installed with a head jamb, sill, and two door jambs. The framing structure of the building being constructed is then drywalled, or fitted with gypsum board, paneling, plywood, or the like. During the drywall phase, drywall is attached to the framing, usually with nails, or screws and using techniques well-known to those of skill in the art. In some embodiments, gypsum board, paneling or plywood is affixed to the framing. 
     Finally, after the drywall is installed, the metal frame or jig is inserted  210  into the doorframe to again confirm that the frame had not moved during the installation of the drywall. This will allow a door of predetermined dimensions to be inserted  212  into the doorframe with proper clearances and fit. The rectangular metal frame inserted into the doorframe may comprise the doorframe jig  100  further described above in relation to  FIG. 1 . The rectangular metal frame may comprise a plurality of beams, girders  112 , and crossbeams  110  as necessary to withstand the compressive and/or tensile forces exerted upon the doorframe during drywalling and during subsequent framing construction. 
     In many embodiments, the doorframe is constructed around a metallic, rectangular doorframe jig which is mounted in place before doorframe construction. The doorframe jig may be mounted on a wooden or concrete constructed surface using nails, clamps, lashing, or compressive forces from structural components adjoining the mounted doorframe jig. Alternatively, the doorframe jig may be mounted to framing components in the structure, such as 2×4s. 
     In some embodiments of the present invention, the doorframe jig  100  is left in the doorframe from the time installation of the doorframe begins until construction on the wall is finished. The jig  100  may be repeatedly reinserted  214  into the doorframe to test the alignment of the components  102 ,  104 ,  106 ,  108 . Finally, after construction is complete, a door is inserted  216  into the doorframe. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.