Adjustable door frame

An adjustable door frame includes a latch jamb, a hinge jamb, two closure jambs, a base header and a closure header, each of which is unitarily formed of sheet metal. The jambs and headers are adjustably connected to accommodate variations in wall thicknesses. Each of the latch jamb, hinge jamb and base header has a flange section overlying the wall, an inside section extending into the doorway opening, a door abutment section extending perpendicularly into the doorway and a tongue section extending perpendicularly from the abutment section. Each of the closure jambs and closure header has a flange section for overlying the opposite wall surface, an inside section extending into the doorway and a folded back section defining a slot frictionally engaging the tongue sections.

FIELD OF THE INVENTION 
The present invention relates to an adjustable door frame formed of sheet 
metal. First and second members form each side jamb assembly and header 
assembly, with the connection between the respective first and second 
members of each assembly being adjustable to compensate for varying wall 
thicknesses. 
BACKGROUND OF THE INVENTION 
Conventional building industry practice uses prefabricated door frame 
assemblies which are manufactured at a manufacturing facility and then 
transported to a remote location for installation. This door frame 
includes a header assembly for the top of the doorway opening and latch 
and hinge jamb assemblies for the sides of the doorway opening in the 
wall. 
The thickness of the wall in which the door is to be located often varies. 
These variations result from variations in the standard materials used as 
well as in the assembly of those materials in forming the walls. To 
accommodate these thickness variations in the wall, the frame must be 
adjustable. 
Additionally, the frame should be adaptable to a wide variety of uses, 
including the addition of a screen or storm door and the addition or 
omission of exterior trim. 
To minimize expenditures in manufacturing, the latch and hinge jamb 
assemblies and the header assembly should be of generally the same 
construction. 
With the increasing cost of wood, metal frames, particularly those of 
steel, have become viable for residential use, as well as for commercial 
use. Thus, the use of metal door frames is expanding. 
SUMMARY OF THE INVENTION 
Accordingly, an object of the present invention is to provide an adjustable 
door frame which can be easily, economically manufactured of sheet metal. 
Another object of the present invention is to provide an adjustable door 
frame with the same structure for the latch jamb, hinge jamb and header 
assemblies. 
A further object of the present invention is to provide an adjustable door 
frame which is adaptable to receive a screen or storm door, and can be 
used with or without exterior trim. 
Yet another object of the present invention is to provide an adjustable 
door frame which is rugged, sturdy, and easy to install. 
The foregoing objects are provided by an adjustable door frame comprising 
first and second members, each of which is unitarily formed of sheet 
metal. The first member includes a first flange section for overlying a 
wall surface adjacent the wall doorway opening, a first inside section 
extending substantially perpendicularly from the first flange section for 
extending into the doorway opening, a first door abutment section 
extending substantially perpendicularly from the first inside section at 
an end thereof remote from the first flange section in a direction 
parallel to and opposite to the first flange section, and a tongue section 
extending substantially perpendicularly from the first abutment section at 
its end remote from the first inside section in a direction parallel to 
and opposite to the first inside section. The second member includes a 
second flange section for overlying the opposite side of the wall, a 
second inside section extending substantially perpendicularly from the 
second flange section for extending into the doorway opening toward and 
adjacent to the first inside section, and a folded back section extending 
from the second inside section at its end remote from the second flange 
section and defining a slot. The slot receives and frictionally engages 
the tongue section of the first member. 
By forming the frame in this matter, the engagement of the tongue section 
in the slot provides an adjustable connection of the first and second 
members. This adjustable connection will compensate for varying wall 
thicknesses, while providing a structure which is sturdy, simple to 
install and manufacture, inexpensive to manufacture, and is highly 
adaptable to varied uses. 
According to a preferred embodiment of the present invention, a groove is 
provided in the first door abutment section adjacent to the respective 
inside section for retaining a seal. This provides the seal in an 
effective location which is stable. 
Other objects, advantages, and salient features of the present invention 
will become apparent from the following detailed description, which, taken 
into conjunction with the annexed drawings, discloses a preferred 
embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION 
The adjustable door frame of the present invention pivotally mounts a door 
10 in a doorway 12 in a wall 14. The door frame includes a latch jamb 
assembly 16, a hinge jamb assembly 18, and a header assembly 20. Each of 
these three assemblies is formed of two mating members. The 
cross-sectional shapes of the two members in each assembly are essentially 
identical. 
The wall 14 having the doorway 12 can be of any conventional form. For 
example, the wall can include wood studs 22 on which dry wall panels 24 
are mounted. The dimensional variations in the studs and dry wall panels, 
as well as the assembly thereof, produce the variations in the thickness 
of the entire wall, that is, between the oppositely directed surfaces of 
the dry wall panels 24. 
As illustrated in FIG. 2, latch jamb assembly 16 comprises a latch jamb 26 
and a closure jamb 28. Latch jamb 26 and closure 28 form the two members 
which are adjustable relative to each other to accommodate for the 
different wall thicknesses and are secured to the wall. Each of the latch 
jamb and closure jamb is unitarily formed from a single piece of sheet 
metal, particularly steel. 
Latch jamb 26 comprises a flange section of 30 which is planar and overlies 
a wall surface adjacent doorway 12 in wall 14. An inside section 32 
extends substantially perpendicularly from first flange section 30 and 
into the doorway. The inside section is also essentially planar. The 
inside section terminates at a door abutment section 34. Door abutment 
section 34 extends perpendicularly from the inside section at its end 
remote from flange section 30. The door abutment section extends in a 
direction parallel to and opposite to flange section 30, i.e., towards the 
center of the doorway and towards hinge jamb assembly 18. A tongue section 
36 is generally planar and extends substantially perpendicularly from door 
abutment section 34 at its end remote from inside section 32. The tongue 
section extends in a direction parallel to and opposite to the inside 
section, i.e., towards closure jamb 28. 
Adjacent the juncture of inside section 32 and door abutment section 34 is 
a groove 38. Groove 38 retains a door seal or weatherseal 40. 
A magnetic weatherseal 40 includes a stem 42 located and retained in groove 
38, a compressible part 44 attached to this stem and extending outside the 
groove and a magnetic part 46 attached to the compressible part. The 
magnetic part overlies the door abutment for engaging the adjacent door 
edge and providing a seal therebetween. 
Groove 48 is defined by portions 48, 50 and 52 of the door abutment 
section. Portions 48 and 52 are generally parallel to each other and to 
inside section 32. Portion 50 joins portions 48 and 52 and is 
perpendicular relative to those two sections. 
Flange section 30 terminates at its end remote from inside section 32 in a 
lip 54. Lip 54 extends substantially perpendicularly from flange section 
30, and is parallel to and extends in the same direction as inside section 
32. 
Latch jamb 26 is mounted to wall 14 with a spacer block 56 located under 
flange section 30. Screws 58 and 60 extend through countersunk holes in 
flange section 30 and inside section 32, respectively, and into wall 14 to 
secure latch jamb 26 in place on the wall. A suitable latch mechanism (not 
illustrated) can be mounted on inside section 32 to mate with a locking 
and latching mechanism conventionally used on doors. 
Closure jamb 28 has a planar flange section 64 overlying a wall surface 
adjacent a side of doorway 12 
substantially perpendicularly from flange section 64 for extending into the 
doorway toward and adjacent to inside section 32 of latch jamb 26. Inside 
section 66 is joined to flange section 64 by two parts 68 and 70, which 
together define a door abutment section. Part 68 extends directly from 
flange section 64 and is substantially perpendicular thereto. Part 70 
extends perpendicularly from part 68 at an end thereof remote from flange 
section 64, and is joined directly to and is perpendicular to inside 
section 66. The door abutment section defined by parts 68 and 70 provides 
a recess for accommodating a screen or storm door. 
Inside section 66 terminates at its end remote from part 70 in a 
180.degree. reverse bend 72 to provide a portion 74 overlying a surface of 
inside section 66 facing the adjacent doorway surface in wall 14. Portion 
74 terminates in a right angle bend from which a portion 76 extends. 
Closure jamb 28 terminates at its free end in a portion 78 which extends 
perpendicularly from the end of portion 76 remote from portion 74 such 
that it is parallel to and opposite to, but spaced from, portion 74. In 
this manner, portions 74, 76, and 78 define a slot therebetween for 
frictionally engaging tongue section 36. 
A lip extends perpendicularly from flange section 64 from its end remote 
from part 68. The lip extends in the same direction as part 68 and inside 
section 66, and extends toward wall 14. 
Spacer block 82 is provided between flange section 64 and wall 14. To 
retain closure jamb 28 in place, screws 84 extend through countersunk 
holes in flange section 64 and into the wall 14, as illustrated. 
Hinge jamb assembly 18 comprises a hinge jamb 86 and a closure jamb 88, 
each of which like latch jamb 26 and closure jamb 28 are unitarily formed 
from single pieces of sheet metal, particularly steel. Hinge jamb 86 is 
constructed with a cross-sectional configuration which is substantially 
identical to latch jamb 26, a except for the preparation for supporting 
the hinges. Like latch jamb 26, hinge jamb 86 has a lip 54, a flange 
section 30, an inside section 32, a door abutment section 34 and a tongue 
section 36. The door abutment section includes a groove 38 adjacent inside 
section 32 formed of portions 48, 50 and 52. The hinge jamb is mounted 
with a spacer block 56 between flange 30 and wall 14, and is secured by 
screws 58 and 60. 
At appropriate locations along the length of hinge jamb 86, its inside 
section has indented portions 90 for accommodating each hinge 92. Hinge 92 
comprises a wall plate 94 mounted in the depression formed by indented 
portion 90 and is secured to the indented portion by screws 96. The door 
plate 98 is secured to the hinged edge of door 10 by screws 100. 
A compression weatherseal 102 is mounted to and attached to door abutment 
section 34 of hinge jamb 86. Compression seal 102 include a stem 104 
secured in hinge jamb groove 38 and a compression part 106 overlying and 
engaging hinge jamb door abutment section 34 and the adjacent surface of 
door 10. 
Closure jamb 88 is identical to closure jamb 28, and includes a lip 80, a 
flange-section 64, parts 68 and 70, inside section 66, bend 72 and 
portions 74, 76 and 78 defining the slot for receiving and frictionally 
engaging tongue section 36 of hinge jamb 86. A spacer block 82 is located 
between flange section 64 and wall 15. Closure jamb 88 is secured to the 
wall by screws 84. 
Header assembly 20 comprises a base header 108 and a closure header 110. 
The base header and the closure header are unitarily formed from single 
pieces of sheet metal, particularly steel, in the same manner as the 
previously described latch jamb 26 and closure jamb 28, respectively. 
The cross-sectional configuration of base header 108 is essentially 
identical to that of latch jamb 26. Specifically, base header 108 includes 
a lip 54, a flange section 30, an inside section 32, a door abutment 
section 34 and a tongue section 36. Base header door abutment section 34 
has a groove 38 adjacent inside section 32 defined by portions 48, 50 and 
52. A magnetic weatherseal 50 is supported on the door abutment section, 
and includes a stem 42 secured in groove 38, a compressible part 44 and a 
magnetic part 46. A spacer block 56 is located between flange section 30 
and wall 14. Base header 108 is secured to wall 14 by screws 58. 
Closure header 110 is essentially identical in cross-sectional 
configuration to closure jambs 28 and 88. Specifically, closure header 110 
includes a lip 80, a flange section 64, secondary door abutment parts 68 
and 70, inside section 66 and a tongue receiving slot defined by bend 72 
and portions 74, 76, and 78. 
A spacer block 82 is located between flange section 64 of closure header 
110 and wall 14. The closure header is secured to the wall by screws 84. 
Each of latch jamb 26, hinge jamb 86, closure jambs 28 and 88, base header 
108 and closure header 110 are separately formed in a suitable 
manufacturing facility. The base header can be attached in a conventional 
manner to the latch and hinge jambs at the installation site or the 
manufacturing facility. Similarly, the closure header can be attached in a 
conventional manner to the closure jambs at the installation site or the 
manufacturing facility. Once the base header-closure jamb assembly and the 
closure header-closure jamb assembly are assembled, the two assemblies are 
connected adjustably by the engagement of the tongue sections 36 in the 
slots. The adjustment provided by the engagement of the tongues and slots 
will accommodate variations in the wall thickness. The mounting screws can 
then be installed to mount and secure the adjustable door frame to wall 14 
in the doorway. 
The lower ends of the hinge and latch jambs and the closure jambs can be 
attached to a threshold assembly extending across the floor of the 
doorway. A typical threshold assembly is illustrated in FIG. 1, and 
comprises an aluminum extender threshold 112 and a vinyl base threshold on 
114. The base threshold 114 engages and mates with a sweep 116 suitably 
mounted on the door to provide a seal at the lower edge of the door. Such 
threshold assembly is typically used on an outside entrance door to 
structure. 
A typical spacer block can have a width of about 1 1/2 inches and a 
thickness of about 1/2 inch. Each of the flange sections typically has a 
width of approximately 2 inches. 
While a particular embodiment has been chosen to illustrate the invention, 
it will be understood by those skilled in the art that various changes and 
modifications can be made therein without departing from the scope of the 
invention as defined in the appended claims.