Door frame assembly

An improved prefabricated door frame construction is disclosed. A frame member is provided which includes a central web spanning the width of the wall and a pair of side flanges which fit over the edges of the wall circumscribing the opening. The web includes a pair of grooves opening in a common transverse direction, one of which is near the center of the web and the other near one edge. Hinge members are provided each having a hinge plate which includes a pair of elongate tongues which engage and mate with the respective grooves of the frame member. Cover plate sections are provided, each of which also has a pair of elongate tongues which engage with the respective grooves. The cover plate sections are cut to fit the gaps between the hinge plates and the ends of the frame member to provide a finished structure.

BACKGROUND OF THE INVENTION 
The present invention relates to door frame assemblies, and in particular 
to an improved prefabricated door frame construction. 
In the construction of interior walls such as those found in offices, and 
in certain exterior construction, the use of prefabricated metal door 
frames has become quite common. Such door frames generally consist of 
extrusions which are provided with slots or countersunk portions so that 
the hinge plates and strike plates can be conveniently installed. An 
example of such a door frame construction is depicted in the patent to 
Cable, U.S. Pat. No. 3,299,592. If the prefabricated door frame does not 
come from the factory with a provision for the installation of hinge 
plates and strike plates, the frame assembly must be cut at the 
construction site so that these items can be installed. 
The door frame assemblies such as that described by Cable are not as 
convenient as desired for several reasons. The door frames must be 
provided in two models, one for left swinging doors and one for right 
swinging doors. Also, because the door frame construction determines where 
the hinges must be located, the hinges must be attached to the door at the 
construction site, and pre-hinged doors cannot be used. In addition, a 
separate model of door frame must be provided to accommodate the hinge and 
strike plate locations of doors of various shapes and sizes because the 
hinge and strike plate positions are fixed when the frame is fabricated. 
In applicant's U.S. Pat. No. 3,287,856, a door frame assembly is depicted 
in which the hinges and strike plates can be located where desired at the 
construction site. Spaces between the hinge and strike plates are covered 
over with cover plate sections to provide an aesthetically pleasing 
finished construction. The principal difficulty with this type of assembly 
is that a certain amount of manual labor is still required to fix the 
hinge and strike plates to the door frame using conventional screw 
fasteners. Moreover, the construction of this door frame assembly is 
relatively complex because the cover plates and hinge strike plates are 
attached to the frame member using discrete connecting mechanisms, each of 
which must be accommodated by the door frame assembly. 
SUMMARY OF THE INVENTION 
The present invention provides an improved prefabricated door frame 
construction. A frame member is provided which includes a central web 
spanning the width of the wall and a pair of side flanges which fit over 
the edges of the wall circumscribing the opening. The web includes a pair 
of grooves opening in a common transverse direction, one of which is near 
the center of the web and the other near one edge. PG,4 Hinge members are 
provided each having a hinge plate which includes a pair of elongate 
tongues which engage and mate with the respective grooves of the frame 
member. Cover plate sections are provided, each of which also has a pair 
of elongate tongues which engage with the respective grooves. The cover 
plate sections are cut to fit the gaps between the hinge plates and the 
ends of the frame member. 
The hinge plates of the present invention can readily be snapped into 
engagement with the frame member at any desired position along its length 
at the construction site. Accordingly, any size or shape door can readily 
be accommodated, and the hinges can be pre-installed on the doors and the 
hinge locations on the frame member matched to their locations on the 
doors. The cover plate sections fill in the spaces between hinge plates, 
giving the entire construction a smooth, finished look. In addition, 
strike plates can be employed having pairs of tongues equivalent to those 
on the hinge plates and cover plate sections so that all portions of the 
door assembly can be installed on the frame member at the construction 
site. 
The apparatus of the present invention greatly facilitates the installation 
of door assemblies. The frame members provided by the present invention 
can be adapted to fit any size or shape door, either left swinging or 
right swinging. Installation of the hinge plates, strike plate, and cover 
plates can readily be accomplished at the construction site with the 
minimum of manual labor. Because of the adaptability of the apparatus, an 
inventory of different frame models is not necessary. 
The novel features which are characteristic of the invention, as to 
organization and method of operation, together with further objects and 
advantages thereof, will be better understood from the following 
description considered in connection with the accompanying drawings which 
a preferred embodiment of the invention is illustrated by way of example. 
It is to be expressly understood, however, that the drawings are for the 
purpose of illustration and description only and are not intended as a 
definition of the limits of the invention.

DESCRIPTION OF THE PREFERRED EMBDOIMENT 
The use of the door frame assembly 10 of the present invention to install a 
door 12 in the opening 14 formed in a wall 16 is illustrated generally by 
way reference to FIG. 1. Door frame assembly 10 includes three frame 
members 18-20 covering the sides and top of door opening 14. A pair of 
hinges 22, 23 are attached to frame member 18 so that door 12 swings in a 
clockwise (looking down from the top) direction. This is generally termed 
a "right swinging" door because it swings to the right of a person opening 
the door from the outside. A strike plate 24 adapted to engage a latch 
actuated by knob 26 is attached to frame member 20 at the opposite side of 
opening 14 from frame member 18. 
Door frame assembly 10 is illustrated in more detail by way of reference to 
FIGS. 2-4 in combination. In FIGS. 2 and 3, door frame member 18 is shown, 
and in FIG. 4, door frame member 20 is shown, all of the door frame 
members being identical metal extrusions. 
Referring specifically to FIGS. 2 and 3 by way of example, each door frame 
member such as 18 includes a central web 26 and a pair of side flanges 27, 
28. Central web 26 spans the entire width of wall 16 and side flanges 27, 
28 extend around the edges of the wall. Each side flange 27, 28 has a 
projecting bead 29, 30 at its extreme end so that frame member 18 can be 
installed by simply snapping it over the end of wall 16. 
Web 26 includes a substantially planar portion 32 extending from side 
flange 27 to approximately the center of the web. At the center of web 26, 
a transversely opening slot 34 is formed which has a serrated 
configuration. Slot 34 extends along the entire length of frame member 18, 
and the plane of the slot coincides with the plane of the planar portion 
32 of central web 26. 
A door stop abuttment 36 is provided at about the center of web 26. Door 
stop abuttment 36 includes a slot 38 in which a resilient door stop pad 40 
can be installed. Slot 38 opens in the same direction of slot 34, i.e., 
opposite from the planar portion 32 of web 26, dictating that the door 
always be located from the side of the web opposite from planar portion 
32. 
Central web 26 of frame member 18 also includes a second transversely 
opening slot 42 at the side of the web adjacent side flange 28. Slot 42 
extends the entire length of frame member 18, and is serrated. The plane 
of slot 42 is parallel to that of slot 34, but is slightly offset toward 
wall 16. 
Web 26 includes a recessed portion 44 which rests flat against wall 16 and 
a shoulder 46 which in combination define slot 42. Shoulder 46 together 
with a connecting portion 48 of web 26 define a planar surface 50 spaced 
slightly inwardly from the planar portion 32 of the web. 
Hinge 22 includes a hinge plate 52 adapted to attach to the frame assembly. 
Hinge plate 52 has a serrated lateral edge 54 which provides a tongue 
adapted to project into and engage serrated slot 34 in frame member 18. In 
addition, projection 55 supports an underlying serrated tongue 56 is 
provided on hinge plate 52 which engages serrated slot 42. Accordingly, 
hinge plate 52 can readily be installed on frame member 18 (or frame 
members 19, 20 since they are identical) at any point along its length 
after the frame member has been installed by snapping the tongues on the 
hinge plate into the grooves in the frame members. The thickness of plate 
52 and the location of projection 55 are such that when the hinge plate is 
installed, except for the engagement rings 57 the visual appearance of 
frame member 18 has mirror symmetry about a plane through its center. 
A plurality of cover plate sections such as 58 are also provided as part of 
the door frame assembly 10 of the present invention. Each cover plate 
section 58 includes a planar portion 60 having a serrated lateral edge 62 
which provides a tongue adapted to engage serrated slot 34 in door frame 
members 18-20. The thickness of planar portion 60 is the same or nearly 
the same as that of hinge plates 52. Cover plate section 60 also includes 
a side flange 64 supporting a projecting serrated tongue 66 adapted to 
engage slot 42 in frame members 18-20. Accordingly, cover plate sections 
58 are attached to the frame members of assembly 10 in the same manner as 
the hinge plates 52. With cover plate sections 58 installed, grooves 34, 
42 are hidden from view and both sides of frame members 18-20 have the 
same visual appearance. No fastener elements are visible, and the external 
appearance of the assembly is clean and attractive. 
The installation of the strike plate 24 in frame member 20 (which is 
identical to frame members 18 and 19) is illustrated by way of reference 
to FIG. 4. Strike plate 24 includes a planar portion 68 having a serrated 
lateral edge 70 which engages groove 34 in frame member 20 (elements of 
frame member 20 are given the same reference numerals as corresponding 
elements in frame member 18). The thickness of planar portion 68 is 
approximately equal to that of planar portion 60 of cover plate sections 
58. Strike plate 24 also includes a curved projection 71 which 
accommodates the sliding latch member used to keep the door in its closed 
position. Strike plate 24 has an underlying serrated tongue 72 adapted to 
engage serrated slot 42. In this fashion, strike plate 24 is attached to 
frame member 20 in the same fashion as hinge plates 52 and cover plate 
sections 58. 
Frame members 18, 19, 20 can be cut from a single piece of stock extrusion 
at the construction site to fit the particular door opening 14 in wall 16. 
Since frame members 18, 19 and 20 are identical, hinges 22, 23 can be 
installed on any of the frame members at any position along their length 
to accommodate various size and shape doors, and left and right swinging 
door applications. Strike plate 24 can similarly be installed where 
desired. After installation of hinges 22, 23 and strike plate 24, cover 
plate sections 58 are cut to fit the spaces between the hinges and strike 
plate and ends of the frame members. The mechanisms by which the cover 
plate sections 58, hinges 22, 23 and strike plate 24 are attached to frame 
members 18-20 is completely hidden from view. Both sides of frame members 
18-20 with equipment attached appear identical, and the completed assembly 
forms a finished, aesthetically pleasing structure. 
While a preferred embodiment of the present invention has been illustrated 
in detail, it is apparent that modifications and adaptations of that 
embodiment will occur to those skilled in the art. However, it is to be 
expressly understood that such modifications and adaptations are within 
the spirit and scope of the present invention, as set forth in the 
following claims.