Adjustable threshold

An adjustable threshold has a lip portion with an adjustable vinyl insert to prevent material from becoming trapped or from engaging a seam present between a floor and a frame member portion adjacent to the floor. The adjustable threshold engages an H-rail trapped in the main U-shaped channel of the frame member which in turn covers and is generally supported by a substrate block. In a preferred embodiment, a first and generally front wall of the frame member is engaged only on one side by a threshold cap. The lip serves to help entrap a second descending wall of the threshold cap and to keep it in place to provide support and stability for the threshold cap. Alternative embodiments exist wherein a lip is advantageously present in a variety of embodiments.

COPYRIGHT AUTHORIZATION

Portions of the disclosure of this patent document may contain material which is subject to copyright and/or mask work protection. The copyright and/or mask work owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright and/or mask work rights whatsoever.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to doorsill assemblies and, in particular, to adjustable thresholds for use in such doorsill assemblies.

2. Description of the Related Art

Over the years, a wide variety of doorsill assemblies have been made with adjustable thresholds. Door sill assemblies were initially designed to fit immediately below an entryway door but are now often extended to adjacent side lights to provide a continuous sill having a uniform, aesthetic appearance while forming a water tight juncture between the sill and the adjoining building floor surface. Such doorsill assemblies also prevent the door from swinging too far forward in the frame so that the hinges are not damaged.

Adjustable sills were developed to provide a threshold which an installer can adjust to fit a specific door. By maintaining a predetermined clearance between the threshold and the door, a door seal can effectively keep out wind and water. Being closest to the ground, the threshold and its juncture with the door is the first line of contact between outside water and cold air and the environment inside the door.

It is desirable that adjustable thresholds be easy to install and adjust, structurally sound, relatively inexpensive and aesthetically pleasing. Another important feature in cold climates is that the threshold should provide a good thermal barrier in order to prevent condensation and icing on the portion of the threshold within the building interior.

With the advent of adjustable sills, it was no longer as necessary to ensure that the measurements of the door, its fit in the frame, or otherwise were exact as the adjustable threshold could be used to provide the seal between the threshold and the door. As a result, construction could be faster, quicker, and even better as the threshold could be adjusted for the best position after the door and threshold had been installed.

SUMMARY OF THE INVENTION

The present invention provides a new construction for an adjustable threshold wherein the same can be used to provide an adjustable threshold for a door construction and the like.

The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new adjustable threshold which has many of the advantages of prior adjustable thresholds as well as many novel features that results in a new adjustable threshold that is not anticipated, rendered obvious, suggested, taught, or even implied by any prior art adjustable thresholds, either alone or taken in any reasonable combination thereof.

In providing manufacturing efficiencies as well as advantages in construction, the adjustable threshold set forth herein has a frame member with a sloped sill resting upon a substrate block. An H-rail or the like is disposed between two abutting elements of the frame member. The two abutting elements slidably engage the H-rail.

Alignment and support walls or members then engage a threshold cap on the interior thereof to keep the threshold cap in place with respect to the frame member. The threshold cap rides up and down generally vertically with respect to the frame member according to adjustment screws threadably inserted into the H-rail. Plugs in the threshold cap allow access to the adjustment screws. A lip of the frame member is present on the inside, or door side, of the adjustable threshold and may engage a vinyl insert of a selectably adjustable size.

The lip helps the adjustable composite tile sill, or the adjustable threshold, to have a unique feature which may be denominated a “tile lip.” This feature allows floor covering material such as ceramic tile, vinyl, wood or carpet, among other materials, to be installed under the sill and to eliminate gaps between the entryway. This also benefits the flooring installers and homeowner as no additional work is necessary to install the flooring material. The feature leaves a seamless finish which is very attractive. The inside tile lip is designed to fit the most common tile size ⅝″ and can be adjusted from ⅛″ high flooring material to ⅝″ with different seal inserts.

In one embodiment of the adjustable threshold set forth herein, an adjustable threshold for use in conjunction with a doorway has a frame member having a main U-shaped channel as well as a vertically-adjustable rail slidably fitting within the main U-shaped channel. A lip is coupled to the main U-shaped channel with a threshold cap engaging the main U-shaped channel and the lip so that adjustment of the vertically adjustable rail adjusts height of the threshold cap.

In another embodiment of the adjustable threshold set forth herein, an adjustable threshold for use in conjunction with a doorway has a substrate block and a frame member covering at least a portion of the substrate block. The frame member has a main U-shaped channel and a sloped sill portion having at least one rib. The rib may be an upwardly extending rib for improved traction and/or a downwardly extending support rib. A shelf coupled to the sloped sill portion may provide a front support for the frame member. The frame member may have a first wall coupled to the sloped sill portion to provide a first side of the main U-shaped channel. A bottom may be coupled to the first wall and provide a bottom to the main U-shaped channel. The bottom may define an adjustment member channel for receiving an adjustment member such as a threaded bolt or screw. A second wall coupled to the bottom may provide a second side of the main U-shaped channel.

The U-shaped channel may have a first abutment member coupled to the first wall, as well as a second abutment member coupled to the second wall, with the first and second abutment members abutting opposite sides of the vertically adjustable rail. The first abutment member may have a first inwardly projecting strip support coupled to a T-shaped head with an upper projection of the T-shaped head projecting away from the vertically adjustable rail. The second abutment member may have a second inwardly projecting strip support similar to the first inwardly projecting strip support coupled to an upwardly-extending projection having a distal end thereof projecting away from the vertically adjustable rail such that the vertically adjustable rail is slidably entrapped between the first and second abutment members.

A vertically adjustable H-shaped rail may slidably fit within the main U-shaped channel. The H-shaped rail may have a left side wall, a right side wall, and a cross member coupled on one side to the left side wall and on another side to the right side wall, the cross member defining a threaded aperture for receiving a threaded adjustment member. The threaded adjustment member may be selected from the group consisting of screws and bolts. The left side wall may have an upward projection terminating in an outward projection for engaging the threshold cap while the right side wall may have an upward projection terminating in an outward projection for engaging the threshold cap.

A lip may be coupled to the main U-shaped channel. The threshold cap may engage the main U-shaped channel and the lip such that adjustment of the vertically adjustable rail adjusts height of the threshold cap. The threshold cap may have a left descending wall, a top coupled to the left descending wall, and a right descending wall coupled to the top with the left descending wall engaging the frame member and the lip and the right descending wall engaging the an external side of the U-shaped channel. The top may define an aperture for receiving a plug.

In an alternative embodiment, the H-shaped rail may be omitted with the U-shaped channel provided a threaded aperture for the adjustment screw or bolt. The threshold cap slidably engages the head of the adjustment screw or bolt which then serves to both support and position the threshold cap with respect to the adjustable threshold as a whole.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

The detailed description set forth below in connection with the appended drawings is intended as a description of presently-preferred embodiments of the invention and is not intended to represent the only forms in which the present invention may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. However, it is to be understood that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the invention.

Referring to the drawings, where like numerals of reference designate like elements throughout it will be noted that the adjustable threshold100has generally a height H measured from the bottom of the substrate block102to the top of the threshold cap104. The height H may also be generally measured from the bottom of the floor F which is generally or often at the same relative height as the bottom of the substrate block102.

Save for its engagement with the ground beneath, the substrate block102is generally circumscribed by the frame member106in the embodiment shown inFIG. 1. The frame member106has a shelf108that undercuts the right most end of the substrate block102.

The shelf108initiates a first end of the frame member106which subsequently rises vertically in front of a substrate block102then travels upwardly at an angle along a sloped sill portion110which may or may not have ribs112traveling along its span. The slope sill110of the frame member106leads into the main threshold portion114of the frame member106. The main threshold portion114is described in more detail below.

The main threshold portion114is also supported by the substrate block102and serves to provide support and stability for the H-rail120. The H-rail120is an embodiment of an adjustment member (or a portion thereof) and may be selectably disposable vertically with respect to the frame member106and the main threshold portion114.

The main threshold portion114is coupled to a lip122to which a vinyl insert124may be selectably attached.

The lip122helps the adjustable composite tile sill, or the adjustable threshold100, to have a unique feature which may be denominated a “tile lip.” This feature allows floor covering material such as ceramic tile, vinyl, wood or carpet, among other materials, to be installed under the sill and to eliminate gaps between the entryway. This also benefits the flooring installers and homeowner as no additional work is necessary to install the flooring material. The feature leaves a seamless finish which is very attractive. The inside tile lip is designed to fit the most common tile size ⅝″ and can be adjusted from ⅛″ high flooring material to ⅝″ with different seal inserts.

The adjustable threshold100is coupled to and/or forms a part of a door sill or other similar system as is known in the art or developed in the future.

The main threshold portion114of the frame member106has a main U-shaped channel130having a first wall132coupled to the sloped sill portion110and a second wall portion134coupled to the lip122and generally adjacent to vinyl insert124. The second wall134has an inward projection136which serves to both abut the H-rail120as well as engage the threshold cap104in conjunction with the lip122. Projecting inwardly from the first wall132, the main threshold portion114has a first, or right side, abutting member140. The abutting member, like most of the structures in the adjustable threshold100, extends laterally (from the viewpoint ofFIG. 1, into and/or out of the page) generally to the extent and span necessary in order to achieve the goals and purposes of the adjustable threshold system set forth herein. The first abutting member140is generally T-shaped in cross-section as indicated inFIG. 1.

The strip142supporting the head144of the first abutting member140projects the head144into the interior of the main threshold portion114to the extent necessary to properly engage or otherwise enable the H-rail120in its capacity to provide vertical adjustment. As shown inFIG. 1, the upper end146of the head144is curved slightly outwardly and away from the H-rail120. The slight curvature enables better insertion of the H-rail120into the main threshold portion114.

This insertion is complemented by an outwardly extending projection148present at the distal end of the inward projection/second abutting member136of the second wall134of the main U-shaped channel130of the main threshold portion114.

The H-rail120is generally held slidably but fixedly and is externally abutted by the first abutting member140and the second abutting member136. From the perspective shown inFIG. 1, the degree of freedom of the H-rail120to travel either left or right is eliminated by the first and second abutting members140,136. However, the H-rail120is free to travel vertically upward and out from the H-rail channel defined between the two abutting members140,136. Similarly, the H-rail may travel laterally between the two abutting members140,136. From the viewpoint ofFIG. 1, this lateral travel of the H-rail120between the two abutting members140,136would be into or out of the plane of the page.

The first wall132of the main channel130may extend upwardly and terminate in a small knob bead or seam160that may extend slightly outwardly from the interior of the main channel130. The first wall132may descend to the substrate block132. The bottom162of the main channel130may travel along the substrate block102in a notched portion164thereof. The bottom162may define an adjustment screw channel166generally central within the bottom162. As for most, if not all, of the structures shown inFIG. 1, the cross-sectional view is meant to portray a cross section of structures that generally extend into and out of the page for the span necessary in order to achieve the present system.

The adjustment screw channel166may descend slightly below the general plane of the bottom162with side walls168,170descending upwardly slightly to restrain an adjustment screw210within the confines of the adjustment screw channel166. The ascent of the side walls168,170is generally limited so that they do not contact the H-rail120when the H-rail120is in its lower-most position within the main threshold portion114. The bottom162of the main threshold portion114and the main U-shaped channel130connects to the second wall134which, as shown inFIG. 1. As shown inFIG. 1, the second wall134descends to the bottom of the substrate block102and generally divides the substrate block102from the floor F. The top180of the second wall generally rises to a height the same or similar as the strip support142of the first or right side abutting member140.

Slightly below the top180of the second wall134, the inward projection136may begin its inward travel towards the interior of the main U-shaped channel130leaving a slight stub or post182present. The lip122may connect to the second wall134slightly below and on the opposite side of the connection of the inward projection136with the second wall134.

The lip may define an open inlet190capable of restrictedly receiving a vinyl insert124. The open inlet may be generally C-shaped in cross-section as shown inFIG. 1in order to entrappingly engage a top projection192of the vinyl insert124. The lip124may also have an upward and inward projection194that projects upwardly and inwardly at an angle from a distal side of the open inlet190, the distal side being the side unattached and away from the second wall134. The lip's upwards and inward projection194may terminate generally above the stub182of the second wall134generally having a flat face surface on a side opposite that of the inward projection/second abutting member136. The lip's upwards and inward projection194may terminate at a height generally slightly below that of the height of the inward projection136.

The H-rail120may have a cross-member or web200that generally travels the span or length of the H-rail120. Generally spaced at regular intervals, threaded apertures202punctuate and perforate the cross member200in order to provide threaded engagement for the adjustment screw210or other adjustment member. The threaded aperture202may have a side support wall220extending upwardly from the threaded aperture202and circumscribing same. The side support wall220may also be threaded as is the aperture202in order to provide support and threaded engagement for the adjustment screw or bolt210. Upwardly extending side walls226,228are attached to the cross member200at a height that generally prevents the left and right side walls168,170of the adjustment screw channel166from contacting the bottom of the cross member200.

However, in an alternative embodiment, such contact may serve to define the bottom or lower most extent or descent of the H-rail120into the main threshold portion114. The bottom most portion or legs232,234of the left and right side walls226,228generally rest against and engage the bottom162of the main U-shaped channel130when the H-rail120is in its lower-most position within the main channel130. The left and right side walls168,170extend upwardly and terminate in T-shaped cross sections238,240. The external arms of these T-shaped portions may have beads or seams similar to that of the bead or seam160so as to provide easy or better engagement of the threshold cap104.

The threshold cap104may be made of plastic, aluminum, or other resilient material and generally has left and right descending walls250,252and a top254that span the necessary or desired distance, generally from the second wall134and the first wall132. In general, the threshold cap104encloses the main U-shaped channel130and the main threshold portion114. The threshold cap104can travel vertically with respect to the frame member106and the main channel130as set forth in more detail below. It is generally limited in the degrees of freedom of its travel in a manner similar to that of the H-rail120as described above with respect to vertical travel and travel into and out of the plane of the page as shown inFIG. 1.

The left descending wall250of the threshold cap104descends generally into the gap between the upward inward projection of the lip194and the inward projection136. The descent of the left descending wall250is limited by the bottom of the inward projection136as shown inFIG. 1and generally in the lower-most position of the threshold cap104. An inward projection or stub260generally entraps the outward projection of the left T-head238of the H-rail120between the inward projection260and the top254of the threshold cap104. A corresponding projection262may serve to entrap the outward T projection of the right T-head240of the right leg234between the inward projection262and the threshold cap top254. In this way, the threshold top104is coupled to the H-rail120and vice versa. Consequently, travel or positioning of the H-rail serves to control the travel and positioning of the threshold top104.

The right descending wall252of the threshold cap104may generally frictionally, snugly and slidably engage the exterior of the first wall132of the frame member106. The bead or seam160may enable visual and or tactile confirmation of the generally safe extent of vertical travel of the threshold cap104with respect to the frame member106. The right descending wall252may terminate in an edge tip270which may flex when the outwardly projecting bead160engages it.

Conversely, the left descending wall250may be thicker in nature so as to provide stability and resilience as the left descending wall250may generally engage (and be somewhat laterally entrapped by) both the upward and inward projection194of the lip122as well as the outwardly extending projection of the inward projection136. This engagement of the left descending wall may serve to stabilize it by the entrapment between these two projections136,194.

The threshold cap104may have plugs (not shown) enabling access to the adjustment screw210. When the adjustment screw210is threaded into the threaded aperture202, it exerts a downward force on the adjustment screw channel166and a corresponding upward force on the H-rail120. Threading the adjustment screw210into the threaded aperture202raises the H-rail120and vice versa. Upon achieving a desired height, the remaining adjustment screws (not shown) may be threaded into their threaded apertures202to the proper height. The plugs (not shown) of the threshold cap104may then be placed back into their apertures thereby generally sealing the threshold cap104. The adjustable threshold100is then ready for use as its height has been achieved and secured. While the adjustment screws210generally do not move during normal use, locking nuts or the like can also be used in order to secure the adjustment screws210in their place and position.

The lip122and vinyl insert124serve to help mediate the transition between the floor F and the adjustable threshold100, and may serve to provide means by which the associated door may be engaged by the adjustable threshold100. The vinyl insert124may keep out dirt, dust, and the like between the seam present between the floor F and the second wall134of the frame member106.

Generally, assembly of the adjustable threshold100occurs with the insertion of the adjustment screws210into their threaded apertures202. The threshold cap104can then be slid upon the H-rail120with its two side walls226,228with their T-heads238,240. The H-rail assembly may then be positioned into the main U-shaped channel130between the two abutting members140,136. By a snap fit or other sliding maneuver, the H-rail120with the threshold cap140is then pressed into the main U-shaped channel130and adjustment of the H-rail120and threshold cap104may begin and be quickly effected.

FIGS. 2-4show alternative embodiments of the embodiment shown inFIG. 1. Note should be taken inFIG. 1that a space292exists between the right inward projection262of the threshold cap104and the top of the first wall132with its bead or seam160. In this embodiment, the right inward projection262does not come into contact with the first wall132.

InFIG. 2, the right inward projection262is omitted entirely, leaving it to the right descending wall252and the left descending wall250with the left inward projection260to hold the threshold cap104in place upon the main U-shaped channel130.

InFIG. 3, the right inward projection262is in contact with the first wall132near its top.

InFIG. 4, the right inward projection262is in contact with the first wall132and the frame member106enjoys some separation from the substrate block102due to descending ribs or walls280present below the sloped sill portion110of the frame member106. A front projection282provides additional sloped sill portion110with channels grooves and/or apertures that may be present for the slidable or other insertion or engagement of additional plastic or other members at the front end284of the frame member106. Note should be taken, that a shelf108is still present in the embodiment shown inFIG. 4that engages a cut-out or notched front end of the substrate block102.

In some embodiments, the adjustable threshold100of the present system may have a minimum height of one and three-eighths inches (1⅜″). The embodiment shown inFIG. 3may have an overall length of approximately three and three-quarter inches (3¾″) while an embodiment such as that shown inFIG. 4may have an overall length of four and five-sixteenths inches (4 5/16″).

FIGS. 5 and 6show an additional alternative embodiment of the present invention, both of which omit the H-shaped rail120. Instead, the adjustment screw210provides an adjustment member and is directly coupled by sliding attachment to the threshold cap304.

In the embodiment shown inFIGS. 5 and 6, the adjustment screw210is threadably attached to a modified U-shaped channel330. The adjustment screw or bolt210slidably engages the threshold cap304adjacent its top354via descending arms310or an otherwise circular (or partially circular) aperture into which the head316may be engaged by the arms or circular aperture310. If a pair of descending arms310is used to gage the head316the adjustment screw210, such arms310may be some what curved or partially circular in nature to better engage the screw head316.

The front alignment wall320may work in conjunction with a front descending wall352to entrap the front wall332of the modified U-shaped channel330. The rear wall334of the modified U-shaped channel330serves to guide and restrain a rear descending wall322of the threshold cap304.

As can be seen from the drawings, rotation of the adjustment screw210causes such a thread around thread from the threaded aperture302. This in turn causes the threshold cap304to raise or lower according to the threaded disposition of the adjustment screw210. In this way, the threshold cap304may be vertically adjusted. A cosmetic cap snuggly insertable into an aperture over the head316of the adjustment screw210(the cosmetic cap not shown) serves to enable access to the slotted or otherwise engageable head316of the adjustment screw210.

FIG. 6is similar toFIG. 5, with the main difference being that the embodiment shown inFIG. 6has a front projection282with a front284in a manner similar to that shown inFIG. 4.FIGS. 5 and 6additionally show the presence of a lip122in a variety of adjustable threshold configurations and embodiments.

While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept.