Synthetic door frame

A synthetic door frame includes an interior channel into which mounting members are fitted for securing the synthetic door frame to a building. The synthetic door frame further includes a cap which fits over the channel and covers the frame mounting members.

FIELD OF THE INVENTION 
The present invention relates to a synthetic door frame. 
BACKGROUND OF THE INVENTION 
Conventional door frames have a wood construction. Some presently available 
wooden door frames may be treated with protective covering material such 
as a thin layer of plastic. 
To date, there is nothing commercially available in the way of a 
synthesized door frame, e.g. a door frame having an all vinyl or similar 
plastic construction. 
In order to mount a conventional wooden door frame, securing members, e.g. 
screws, are threaded through the frame into the surrounding building wall. 
Further steps are then taken to patch the door frame for purposes of 
hiding the mounting screws. 
For new building construction, doors are generally sold already mounted in 
a surrounding door frame. For installation of the combination door and 
door frame, the frame is levelled and then mounted with the door held 
open. The reason the door must be held open is to gain access to the 
interior of the frame immediately surrounding the door where the screws 
are located in the frame. This method of door mounting is awkward, labour 
intensive and cost inefficient. 
SUMMARY OF THE INVENTION 
The present invention provides a synthesized, preferably vinyl, door frame 
which is much simpler and easier to mount than existing door frames. More 
particularly, the synthesized door frame of the present invention includes 
at least one interior channel where the mounting screws are located and 
further includes a cap which fits over the channel and hides the mounting 
screws. 
According to a preferred aspect of the present invention, the synthesized 
door frame includes first and second interior channels with a covering cap 
for each of the channels. The second interior channel may provide an area 
for an initial hanging of the frame with the frame levelled and the door 
in a closed position. With the door closed, it is much easier to maintain 
the level position of the frame. 
After the door has been initially hung at the second channel, the door is 
opened and the final hanging of the door is completed by fitting mounting 
screws in the first channel immediately around the door perimeter. The 
covering caps are then fitted over both channels to hide all of the 
mounting screws.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
FIG. 1 shows a door with synthesized frame assembly generally indicated at 
1 ready for installation in a building BD. The assembly 1 comprises the 
door 3 and the synthetic frame 5. The door itself preferably has a metal 
construction although other materials can be used in the door. 
The term synthesized used in association with frame relates to any man made 
shape formable material. In the preferred embodiment the frame has a vinyl 
or similar thermosettable plastic material construction. 
The details of synthesized frame 5 are best seen in FIGS. 2 and 3 of the 
drawings. The frame comprises first and second frame portions 7 and 23 
which are divided by a door stop 21. The frame portions and door stop 
comprise a single integral construction. 
The first frame portion 7 is in all embodiments used as a door mounting 
region for the door 3. The second frame portion 23 may be used to provide 
an initial mounting of the frame to the building, after the frame and door 
have been set to a level position. This initial mounting is achieved with 
the door held in its closed position as shown in FIG. 2 of the drawings 
and then the final mounting or securing of the frame is accomplished at 
the first frame portion with the door in an opened position as shown in 
FIG. 3. However, when the door is moved to the open position, the level 
positioning of the frame and door is maintained by the initial mounting at 
the second frame portion 23. 
In terms of a more detailed description, each of the frame portions 
includes an interior channel to opposite sides of the frame where a 
channel generally indicated at 9 is provided in frame portion 7 and a 
channel generally indicated at 25 is provided in frame portion 23. After 
installation, the entirety of channel 25 is covered by a snap cap 37 
having a pair of interior lips 39 which lock on to lips 27 to opposite 
sides of channel 25. 
Channel 9 in frame portion 7 is over much of its length, i.e. at areas 
other than the hinges and the striker plate, covered by the identical cap 
37. In this case the cap lips 39 lock onto inwardly extending lips 15 
provided at the outer edges of channel 9. Provided interiorly of channel 9 
are two sets of ribs including a first set of taller ribs 11 and a second 
set of ribs 13 which are shorter than the ribs 11. 
The first frame portion 7 includes an outer facing 17 having an undercut 
channel 19. The second frame portion 23 includes an outer facing 29 having 
an undercut channel 31. Channel 31 is identical to channel 19 and 
therefore these two channels are capable of receiving the same type of 
trim accessories, some of which are described below. 
Before going into the actual mounting details, further reference is had to 
FIG. 6 of the drawings showing the hinge mounting area in the frame and 
further showing safety features of the frame. In particular, the first 
frame portion 7 includes a hollow interior region generally indicated at 
8. This hollow region is designed to receive different types of 
reinforcements for the synthesized frame. In one embodiment where the door 
requires a fire safety rating, a length of channel shaped steel plate 10a 
is inserted in the hollow 8 which prevents the frame from buckling when 
subjected to intense heat as would occur in the case of a fire. If the 
door does not material 10b is used as an alternative stiffener which again 
fits within the hollow interior 8 of frame portion 7. 
FIGS. 2 and 3 of the drawings show that the door 3 is mounted to the frame 
5 by means of a hinge generally indicated at 45. Again, referring to FIG. 
6 of the drawings, hinge 45 includes a door mounting leg 46 and a frame 
mounting leg 47. The first frame portion 7 of the door frame is cut away 
as indicated at 49 to remove the interior edge of the front facing and to 
additionally cut down the depth of the two taller ribs 11 in the channel 9 
of frame portion 7. The ribs 11 are cut back so that they are the same 
height as the shorter interior ribs 13 which allows a flush mounting of 
leg 47 on hinge 45 across the door frame. The cap 37 is then placed to 
opposite sides of the hinge, i.e. above and below the hinge, which gives 
the hinge a mortise like appearance as if it was built directly into the 
frame flush with the channel cap. 
Although not shown, frame portion 7 is additionally fitted with a striker 
plate and the frame portion will again be cut away to receive the striker 
plate. However, because the striker plate is of thinner material than the 
hinge, the striker plate will seat on ribs 11 which do not need to be cut 
back and which locate the striker plate at a level once again flush with 
cap 37 to opposite sides of the striker plate. Accordingly, the striker 
plate, like the hinges, has a mortised appearance on the door frame. 
The installation steps for mounting door and frame assembly 1 include an 
initial levelling of the frame with the door in its closed position. Once 
the frame has been levelled and keeping the door closed as shown in FIG. 2 
of the drawings, a first set of mounting screws 41 are screwed through the 
frame portion 23 into the surrounding building material. These screws 41 
are located in the channel 25 of the frame portion 23. This frame portion 
is provided with internal ribs 26 through which the screw are threaded 
providing a very positive engagement for the screws and stiffening the 
frame portion in this area against inward collapsing as shown in FIG. 2 of 
the drawings. 
After the frame portion has been initially secured and hung by screws 41, 
the door can then be swung open with the frame holding its level position 
and allowing access to the channel 9 in the first frame portion for 
insertion of further screws 43. These screws are fitted between the two 
shorter ribs 13 which provide a guide for the screws. Screws 43 also fit 
through the reinforcing steel plate or wood core in the hollow of the 
first frame portion into the building material outside of the frame. 
Screws 43 therefore provide a final stabilized mounting of the frame. 
After the frame has been installed as described immediately above, the 
channel caps 37 are snapped into position. These channel caps although 
easily installed require a substantial effort to remove to guard against 
tampering and unauthorized access by removing the screws hidden by the 
caps. Furthermore, the screws in frame portion 7 are not accessible once 
the door is closed. 
From an aesthetic standpoint, caps 37 are extremely beneficial in that they 
hide the door mounting screws eliminating the necessity to patch the door 
as found with conventional wooden door frames. 
One of the very beneficial features provided by frame 5 is that it is 
reversible for use in supporting either an outswinging or an inswinging 
door. Both of these terms are used relative to the outside of the building 
i.e. swing out or swing in relative to the building exterior. 
FIGS. 4 and 5 of the drawing show slightly modified door frames 5a and 5b. 
Each of these frames is mounted in a building having an exterior brick 
facing BR which is secured to the building after mounting the frame. The 
door supported by frame 5a in FIG. 4 is an inswinging door and the door 
supported by frame 5b in FIG. 5 is an outswing door. 
Door frame 5a includes first and second frame portions 7a and 23a. Provided 
between the frame portions is a door stop 21a. 
In this particular arrangement, the channel region 25a of frame portion 23a 
is not necessarily used in the initial securing of the frame. Rather a 
facia member 51 having a nailing fin 52 is provided to the outer edge of 
the frame portion 23a. When the frame is levelled, mounting screws 44 are 
screwed through the nailing fin 52 into the building to hold the level 
position of the frame. Again, this is done with the door in a closed 
position. In order to provide a final securing of the door, it is opened 
and screws 43 are inserted in the channel 9a of the first frame portion 
7a. The cap 37 identical to the earlier cap is then fitted over channel 
9a. 
In this particular arrangement, although not necessary, additional mounting 
screws may still be mounted in the channel 25a of the second frame portion 
23a and hidden by cap 37. 
The brick facia member 51 includes a small leg 54 insertable in the channel 
31a of the forward facing 29a on the door frame. It further includes a 
second leg 53 which sets to the outside of and is secured to the frame as, 
for example, by stapling to the frame. The brick facing is seated over 
nailing fin 52 after screws 44 had been threaded into place. 
In FIG. 5, door frame 5b is similar to frame 5a but reversed in its 
direction of installation. This again is a very beneficial feature of the 
vinyl frame of the present invention in that it is reversible according to 
whether or not one wishes to mount an inswinging or an outswinging door. 
FIG. 5b shows a modification of the present invention where the initial as 
well as the final door hanging is all done at the same side of the frame. 
More particularly, with the set up of frame 5b, frame portion 7b faces to 
the outside of the building and is fitted with the brick facia member 51 
having the nailing fin 52. Again, this nailing fin is used to receive 
screws 44 for setting up and holding a squared or level position for the 
door frame with the door in its closed position. Once the level position 
has been established and held by the nailing fin, the door is opened and 
final mounting screws 43 are secured in the channel 9a through the frame 
reinforcing member and into the building itself. Screws 43 are then 
covered by cap 37. Additional screws may be fitted into the channel 25b of 
the frame portion 23b simply to insure that this frame portion does not 
lift away from the building. 
In all mounting installations, a sealing strip is provided on the door stop 
as shown. The sealing strip on the door stop away from the hinge side of 
the door further includes a magnetic strip to provide a positive door 
closure. As earlier described, the door may have a metal construction or 
at least a metal strip which is attracted to the magnetic sealing strip on 
the door frame. The sealing strip arrangement, except for its orientation, 
remains the same regardless of the direction in which the frame is 
installed relative to the building as can be seen, for example, in 
comparing FIGS. 4 and 5. 
FIGS. 7 and 8 show a further feature of the present invention in which 
assembly 1, including door 3 and frame 5, are attached to a further frame 
5c carrying a side window 50 for installation in a building. In this 
particular arrangement, the securing is provided at the outer sides of 
frame 5 and frame 5c respectively. As can be seen FIG. 8 of the drawings, 
these two frames are identical in construction although frame 5c is 
narrower than frame 5 and the method of securing at both frames is the 
same as that described above. 
In FIG. 8, it will be seen that the first frame portion 7c of frame 5c 
includes an outer facing 17c with an undercut channel 19c. The second 
frame portion 23c includes a facing portion 29c with an undercut channel 
31c. Facing portion 29c is located to the inside of the building. 
Connecting pieces 53 fit into the undercut channels at the aligned facings 
of the two frames 5 and 5c to connect the frames with one another. 
Additionally provided are mechanical fasteners 57 and 59 in the first and 
second channel regions respectively of the two frames. Mechanical 
connectors 59 are then covered by caps 37 as shown. The mechanical 
connectors 57 are covered by a cap 37 on frame 5 and by a combination cap 
and blocking member 55 on frame 5c. 
Frame 5c includes a stop 21c which, rather than being a door stop, provides 
a window edge stop or guide for window 50. The window is therefore trapped 
in position between stop 21c and the capping member 55 which includes lip 
56 that interlocks with the lips 15c on the frame portion 7c of the frame 
5c. This same securing arrangement is provided at the other side of frame 
5c for holding the opposite edge of window 50. 
With the set up as described immediately above, the door and side window 
combination is mounted as a single unit to the building. 
Although various preferred embodiments of the present invention have been 
described herein in detail, it will be appreciated by those skilled in the 
art, that variations may be made thereto without departing from the spirit 
of the invention or the scope of the appended claims.