Method and apparatus for mounting a door frame in a building

The present invention provides a method and apparatus for mounting a door frame into a door opening of a building and includes a pair of substantially similar brackets, a door support frame, and a trim frame. The brackets are connectable to the door opening, the door support frame is connected to the brackets, and the trim frame is connected to the door support frame. The brackets may have a slotted aperture for adjusting the brackets horizontally along a fastener. The brackets may also have an inward taper or ramp for adjustably receiving the door support frame. The brackets are connected to the door support frame through the use of mounting pins, slots, spring clips, integral pins, or a frame insertion tab.

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for mounting a door frame in an opening of a building, and more particularly, a method and apparatus that provides for the rapid installation of a steel door frame into a doorway of a building that requires a minimal amount of labor and time for installation.

BACKGROUND

Welded steel door frame systems are widely used in the construction of commercial buildings. These welded steel door frames are known for their high-strength, long service life, and one-piece finished appearance. Non-welded steel frame door systems are known to be used in the commercial construction industry as well, such as knocked down or multi-pieced designs, but such designs are not perceived as delivering the same value and benefits as a welded steel door frame system.

The installation of these welded steel door frame systems is labor intensive and driven by a complex logistics process. For instance, the design and construction of a typical one-piece steel door frame requires the door frame to be installed during the process of constructing the walls of the building which surround the door frame. As a result, the installation of the steel door frame must take place well in advance of the installation of the associated doors and door hardware. Because the steel door frames are installed early in the construction process, the steel door frames are susceptible to damage from construction activities taking place in and around the door openings.

In addition, the installation of a steel door frame typically requires multiple steps. That is, the steel door frames must first be assembled and installed, and then the associated doors are subsequently installed with their respective hardware. This typically requires several deliveries to the construction site due to the multiple component nature of the door frames and the associated door and hardware. Due to the weight of the door frame and the associated door, as well as the complexity of assembling the door frame and the associated door, the installation of the door frame and the door typically requires at least two laborers and multiple trips to and from the door opening to acquire and install the necessary components. Such installations are therefore inefficient and undesirable in the building industry.

As previously noted, there are typically a number of components involved in assembling the steel door frame, as well as the associated door and hardware. Thus, the site logistics for such components can be difficult, as the frames are often delivered to the job site in large quantities and have to be stored on site where storage space is typically limited. Often such components are moved numerous times prior to the installation of the door frame and associated door and hardware, thereby subjecting the components to possible damage and loss. This, of course, creates further inefficiencies that are undesirable in the building industry.

In light of these problems and inefficiencies with installing steel door frames and their associated doors and hardware, it would be desirable to provide a method and apparatus for mounting a steel door frame to a doorway in a building that reduced the total project costs, shortened construction lead times, improved installed quality, and created more efficient site logistics to increase the efficiency of installing such steel door frames.

SUMMARY OF THE INVENTION

The present invention provides a method and apparatus for mounting a door frame into a door opening of a building wherein the door opening is defined by a pair of substantially parallel side surfaces of the walls, and a floor substantially parallel to a top surface of the walls, wherein the floor and the top surface extend between the side surfaces of the walls. The present invention includes a pair of substantially similar brackets, wherein each one of the brackets is connectable to one of the pair of side surfaces of the wall. A door support frame is connected to the brackets, and a trim frame is connected to the door support frame for securing the trim frame in the door opening of the building.

Each of the brackets may include a slotted aperture for receiving a fastener connectable to the walls wherein the brackets may adjustably slide along the fastener relative to the side surfaces of the walls. Each of the brackets may have an inward taper or ramp that allows an end portion of each bracket to extend inward and away from the side surfaces of the walls for engaging the door support frame.

Each of the brackets may have one of a mounting pin or a slot formed therein, and the door support frame may have the other of the mounting pin or slot formed therein, such that the mounting pin engages the slot, thereby connecting the door support frame to the brackets. Each of the mounting pins may have a substantially circular head connected to a smaller stem, wherein the stem is smaller than the slot for engaging the slot, and the head is larger than the slot to prevent the head from passing through the slot, thereby connecting the door support frame to the brackets. Each of the slots may have an open-ended portion extending angularly downward or horizontal with an upward, closed-ended portion in communication with the angularly downward or horizontal portion of the slot.

The door support frame may have a generally U-shaped configuration that extends along the side surfaces, top surface, and front surface of the walls and a generally L-shaped cross-sectional configuration with a short leg and long leg. A substantially rectangular jamb is connected to the longer leg of the door support frame. The trim frame may extend between the jamb and the longer leg of the door support frame to connect the trim frame to the door support frame.

DETAILED DESCRIPTION

The present invention provides a method and apparatus10for mounting a door frame12into a door opening14of a building (not shown). As seen inFIGS. 1-9, the method and apparatus10of the present invention is utilized to increase the efficiency of mounting the door frame12into the door opening14of the building. The method and apparatus10of the present invention provides a pair of substantially similar brackets18that are adjustably mounted to walls28of the building defining the door opening14. Each of the brackets18has a mounting pin20that extends inward toward the door opening14wherein the mounting pins20directly oppose one another. A three-sided door support frame22is received by the door opening14and may be mounted within the door opening14with or without a door (not shown) connected to the door support frame22. The door support frame22is connected to the brackets18by having opposing slots24formed in the door support frame22. The mounting pins20on the brackets18are received by the slots24in the door support frame22, thereby positioning and securing the door support frame22onto the brackets18and into the door opening14of the building. A three-sided trim frame26is received from the opposite side of the door opening14, and the trim frame26is connected to the door support frame22to secure the trim frame26to the door support frame22and the brackets18. Once fully installed, the door frame12is ready to have the door connected to the door frame12through the use of hinges (not shown) and associated hardware (not shown) if the door was not previously connected to the door support frame22. If the door was previously connected to the door support frame22, then only the associated door hardware need be assembled to the door.

The method and apparatus10of the present invention may be used to install the door frame12into the door opening14of the building, as seen inFIG. 1. The door opening14is defined by a pair of the opposing walls28, which may be constructed from wood or steel, wherein plasterboard16may cover the outer surfaces of the walls28. The door opening14is further defined by the width30between the opposing walls28and the depth32defined by the width of the walls28. The width30and depth32of the door opening14typically have “rough” or approximate dimensioning, meaning that these dimensions do not have a fine tolerance specification. The door opening14is further defined by the walls28having a front surface34, a side surface36, and a rear surface38. The door opening14is also defined by a floor40of the building and a top surface (not shown) of the walls28. The floor40and the top surface extend between the side surfaces36of the walls28defining the door opening14. Although the walls28of the building have been described as being fabricated from wood or steel with the plasterboard16applied to the front and rear surfaces34,38of the walls28, it is anticipated that the walls28may be fabricated from any other conventional materials used in the construction industry.

In order to mount the method and apparatus10of the present invention into the door opening14of the building, the brackets18are mounted within the door opening14, as seen in FIG.2. The brackets18consist of two, substantially similar brackets18wherein each bracket18extends along almost the entire length of one of the opposing side surfaces36of the walls28defining the door opening14. The brackets18have a continuous one-piece configuration and are fabricated from a high-strength, lightweight material, such as aluminum or steel. The brackets18have an elongated, substantially L-shaped cross-sectional configuration wherein a short leg or flange42of the brackets18extends adjacent along the front surface34of the wall28. A slotted aperture44is provided in and through the flange42of the bracket18, and a conventional fastener46extends through the slotted aperture44and the front surface34of the wall28and into the wall28of the building to secure the brackets18to the wall28. The slotted aperture44in the flange42of the bracket18allows the brackets18to slide horizontally relative to the fastener46, thereby providing adjustment of the brackets18along the width30of the door opening14to and from a centerline of the door opening14such that the distance between the brackets18can be adjusted accordingly. A long leg47of the L-shaped cross-sectional configuration of each of the brackets18may have an inward taper or ramp48which allows an end portion49of the brackets18to extend inward toward one another and away from the side surface36of the walls28defining the door opening14. The ramp48on each of the brackets18may be utilized to assist in the assembly of the door support frame22by guiding the door support frame22into a proper position within the door opening14, as will be subsequently described. The mounting pins20are connected at the end portion49of the brackets18and extend inward into the door opening14toward one another. The mounting pins20have a substantially circular head50connected to a smaller stem52which is connected to the bracket18. The mounting pins20of each bracket18directly oppose one another at a specific and predetermined distance within the door opening14.

To secure the door support frame22to the brackets18, the door support frame22is inserted into the door opening14from the front surface34of the walls28, as seen inFIG. 3. The door support frame22may be fabricated from a high-strength, lightweight material, such as steel or aluminum, or it may be fabricated from other conventional building materials, such as wood. The door support frame22has a three-sided, substantially U-shaped configuration which extends along the side surfaces36, the top surface, and the front surface34of the walls28. Each one of the three sides of the door support frame22has a generally L-shaped cross-sectional configuration, wherein a shorter leg53of the L-shaped configuration of the door support frame22extends across and adjacent to the front surface34of the walls28. A longer leg55of the L-shaped configuration of the door support frame22extends into the door opening14along the side surfaces36and top surface of the walls28and provides a bracket connecting portion54welded to a jamb56. The jamb56has a substantially rectangular configuration and extends further into the door opening14along the width30of the door opening14. The bracket connecting portion54of the door support frame22has the slot24formed in an end57of the door support frame22adjacent the mounting pin20of the bracket18. The slot24of the door support frame22has an open-ended portion59extending angularly downward with an upward, closed-ended portion61in communication with the downwardly extending portion59of the slot24, as seen inFIGS. 3A-3C. The mounting pin20engages the slot24by having the stem52of the mounting pin20enter the slot24at the open-ended portion of the slot24, as seen inFIG. 3A, while the head50of the mounting pin20extends beyond the slot24. The head50of the mounting pin20is larger than the slot24, thereby preventing the head50of the mounting pin20from passing through the slot24and maintaining the stem52of the mounting pin20within the slot24. The door support frame22is moved or lifted upward, as seen inFIG. 3B, thereby moving the mounting pin20down the slot24until the mounting pin20reaches the end of the downward portion59of the slot24. The door support frame22is then moved downward such that the mounting pins20rest in the upward, closed-ended portion61of the slot24, as seen inFIG. 3C. The configuration of the mounting pins20and slots24provides a “lift and drop” feature, wherein the door support frame22is lifted to allow the mounting pins20to engage the downward portion59of the slot24. The door support frame22is then lowered to allow the mounting pins20to engage and rest in the closed-ended portion of the slots24. Thus, the door support frame22is allowed to sit and hang from the mounting pins20of the brackets18without having the bottom of the door support frame22contacting the floor40of the building. This ensures that the door frame12will remain level and substantially perpendicular. The method and apparatus10also allows an installer to install the door support frame22with a door mounted thereon, and once the door support frame22is mounted to the bracket18, the door support frame22will not fall back out of the door opening14. In addition, the method and apparatus10secures the door support frame22to the brackets18without the need for a second installer.

In an alternative embodiment, the slot24in the door support frame22may have an open-ended substantially horizontal portion67with an upward, closed-ended portion61at the end of the slot24, as seen inFIG. 3D. This allows the door support frame22to be slid horizontally along the mounting pins20and then dropped into position as opposed to lifting and dropping the door support frame22, as described in the previous embodiment.

In other alternative embodiments, various clip and pin configurations may be utilized, as seen inFIGS. 3E-3O. InFIGS. 3E-3F, a spring clip64with an integral pin66mounted on the door support frame22is used to engage the pin66within a hole68provided in the bracket18. InFIGS. 3G-3H, a spring clip80mounted on the door support frame22engages a pin81on the bracket18. InFIGS. 3I-3J, a spring clip82is mounted on the door support frame22to engage an edge of the bracket18.

In yet another alternative embodiment, a pair of similar frame insertion tabs85may be used to secure each of the brackets18to the door support frame22as seen inFIGS. 3K-3O. In this embodiment, a pair of substantially similar slots90is formed in each of the brackets18. The slots90consist of substantially similar rectangular apertures extending through the long leg47of each the brackets18for receiving the frame insertion tabs85. The slots90are located near the center of each bracket18, and a portion91of the brackets18located between the slots90may be raised, lowered, or flush to the brackets18. The frame insertion tabs85are connected to each side of the door support frame22. The frame insertion tabs85have a substantially toothed configuration such that the frame insertion tabs85can pass through the slots90in the brackets18. The frame insertion tabs85have a first end83, a second end84, a top edge89, and a bottom edge86. Along the bottom edge86of each frame insertion tab85, there are two substantially similar, rectangular recesses88. A tooth87is formed along the bottom edge86between the rectangular recesses88. The first end83of the frame insertion tab85partially extends angularly downward toward the bottom edge86adjacent to one of the rectangular recesses88.

To secure the door support frame22to the brackets18, the frame insertion tabs85engage the slots90in the brackets18, as shown inFIGS. 3L-3N. The door support frame22is raised slightly, so that the frame insertion tabs85can pass through the slots90in the brackets18, as shown inFIG. 3M. After the first end83of the frame insertion tab85has passed through both slots90in the bracket18, and the tooth87is positioned between the slots90in the bracket18, the door support frame22is lowered, as shown inFIG. 3N, allowing the rectangular recesses88on the frame insertion tab85to be seated in the slots90in the brackets18.

Various themes and features of these designs are also anticipated. For instance, the mounting pin20and the slot24can be reversed such that the brackets18contain the slot24, and the door support frame22contains the mounting pins20. In addition, the spring clips80,82and the mounting pins20can also be reversed such that the spring clips80,82are mounted on the brackets18, and the mounting pins20are mounted on the door support frame22. The frame insertion tabs85and the slots90can be reversed such that the slots90are on the end57of the door support frame22and the frame insertion tabs85are on the brackets18. Similarly, it is anticipated that the number of slots90and teeth87could be increased or decreased. If there is only one slot90in the bracket18, only one rectangular recess88in the frame insertion tab85is needed. The rectangular recess88will rest in the slot90when the door support frame22is secured to the brackets18, as seen inFIG. 30.

Once the door support frame22is connected to the brackets18via one of the above-noted embodiments, conventional fasteners58may be inserted through corresponding apertures (not shown) in the brackets18and the door support frame22, wherein the fasteners58are driven through the side surfaces36of the walls28and into the walls28defining the door opening14to secure the brackets18and the door support frame22to the walls28of the building, as seen inFIG. 4.

In order to install the trim frame26to the door support frame22, the trim frame26is inserted from the rear surface38of the walls28defining the door opening14of the building, as seen inFIG. 5. The trim frame26is also three-sided with a substantially U-shaped configuration, such that the trim frame26extends along the side surfaces36and the top surface of the walls28defining the door opening14. The trim frame26also has a generally L-shaped cross-sectional configuration, wherein a short leg70of the L-shaped configuration extends along the rear surface38of the walls28defining the door opening14, and a long leg72of the L-shaped configuration extends along the entire side surfaces36and top surface of the walls28defining the door opening14. The trim frame26is also made of a lightweight, high-strength material, such as aluminum or steel; however, the trim frame26may also be fabricated from wood or any other conventional construction material. The long leg72of the trim frame26is inserted through a gap74provided between the bracket connecting portion54and the jamb56of the door support frame22. The end76of the long leg72of the trim frame26may have a plurality of slots60formed therein. The slots60in the trim frame26may be received by locking tabs65formed on a raised ridge63on the bracket connecting portion54of the door support frame22within the jamb56, as seen inFIGS. 6A-6C. The plurality of slots60in the trim frame26allow for adjustment of the trim frame26relative to the door support frame22by inserting the trim frame26further into the gap74formed between the bracket connecting portion54and the jamb56of the door support frame22, as seen inFIGS. 7A-7E. The engagement of the slots60and locking tabs65provide a ratcheting effect, thereby allowing for easy positional adjustment of the trim frame26relative to the door support frame22in three possible positions, as shown inFIGS. 7A-7C. The locking tabs62on the bracket connecting portion54of the door support frame22engage the slots60in the trim frame26. The trim frame26is the same size as the door support frame22, so when the trim frame26is connected to the door support frame22, the trim frame26will also hang from the door support frame22off the floor40of the building. Again, this will ensure that the trim frame26remains level and substantially perpendicular as well. Once the trim frame26is securely connected to the door support frame22, the method and apparatus10of the present invention is complete.

In operation, the brackets18are mounted in the door opening14of the building by having the fasteners46connect the brackets18to the front surface34of the walls28defining the door opening14of the building. When doing so, one of the brackets18is mounted directly adjacent to, but not touching, the higher side of the floor40defining the door opening14. Once one of the brackets18is mounted adjacent to the highest side of the floor40, the other bracket18may be mounted at the same height directly across from and substantially parallel to the opposing bracket18. Once the height of the brackets18are determined, then the distance between the brackets18or the width30of the door opening14may be adjusted by sliding the brackets18along the fasteners46positioned in the slotted apertures44of the brackets18. The fasteners46are then threaded through the front surface34of the wall28and into the wall28of the building to secure the brackets18to the walls28. The door support frame22is moved into position for assembly to the brackets18by moving the door support frame22toward the front surface34of the wall28defining the door opening14and engaging the ramp48of the bracket18to guide the door support frame22into a proper position within the door opening14. The ramp48and the slotted apertures44in the bracket18provide a means to create the perfect dimension between the brackets18. The door support frame22is positioned such that the slots24in the door support frame22are positioned adjacent to the mounting pins20on the brackets18. The mounting pins20on the brackets18are received in the open-ended slots24of the door support frame22and slid into position at the closed-ended portion of the slots24, thereby allowing the door support frame22to sit and hang from the mounting pins20. The fasteners58are inserted through corresponding apertures in the brackets18and the door support frame22and through the side surfaces36of the walls28and into the walls28to secure the brackets18and the door support frame22to the walls28of the building. The trim frame26is then brought in from the rear surface38of the walls28defining the door opening14such that the long leg72of the L-shaped configuration of the trim frame26is inserted through the gap74between the bracket connecting portion54and the jamb56of the door support frame22. The slots60in the long leg72of the trim frame26are engaged by the locking tabs62on the raised ridge63of the door support frame22so as to secure the trim frame26to the door support frame22. The trim frame26is pushed toward the door support frame22, thereby ratcheting the locking tabs62along the slots60of the trim frame26until the trim frame26is in the proper position, wherein the trim frame26hangs with and from the door support frame22. The assembly of the method and apparatus10of the present invention is then complete.