Door frame assembly

A channel assembly for framing a doorway includes a primary frame element having adjacent inside and outside channel sections respectively provided with trim sections adapted to overlie inside and outside walls. A separate door stop member includes hook elements engageable with catch devices integral with one such channel section to permit removable attachment of the stop member. Hinge and strike provisions are achieved through a separate plate also having hook elements and which are snap-fittedly engageable with catch devices integral with the inside channel section such that any of various customized hinge and strike provisions may be provided with any one frame element. The frame element may comprise a unitary member for installation with a fixed wall thickness or, separate inside and outside channel sections slidably overlapping one another to permit accommodation of varying wall thicknesses. In either instance, trim sections normal to the ends of the frame element provide a finish trim overlying the wallboards and this trim may comprise and integral portion of the frame element or include separate, snap-on members.

FIELD OF THE INVENTION 
This invention relates generally to door frames and more particularly, to 
an improved door frame assembly having removable and replaceable hinge and 
strike provisions in combination with a replaceable door stop element, 
with or without the inclusion of adjustment means permitting accommodating 
varied wall thicknesses with the same assembly. 
BACKGROUND OF THE INVENTION 
Metal door frame assemblies, whether adjustable or not, are usually 
fabricated from sheet metal which is formed to provide one or more 
components defining inside and outside channels with one such channel 
formed to provide an integral door stop member. As is well known, that 
portion of the inside channel adjacent the stop member will serve either 
as the strike or hinge wall of the channel, depending upon which side of a 
door opening the respective frame assembly channels are mounted and 
whether the intended door will be a left-hand or right-hand opening door. 
Some frame assemblies are manufactured with more or less standard hinge 
and strike provisions. That is, one channel will be provided with a cutout 
forming the strike provision and which is adapted to receive the bolt of a 
door latch. Often, two tapped holes are included adjacent this hole for 
mounting of a strike plate having an opening aligning with the channel 
hole. Pre-defined hinge provisions are also common and wherein either two 
or three specifically spaced apart openings or recesses are provided in a 
channel, with or without tapped screw bores. These openings or recesses 
are frequently reinforced by backup plates, particularly when a metal door 
installation is involved. 
In any of the above situations wherein hinge and strike provisions are 
already supplied, a user is confined to employing doors having hinges and 
latch/bolt devices precisely matching the size, location and spacing in 
agreement with the cooperating provisions on the door channels. If a 
customer decides to use a lighter weight two-hinge door and the contractor 
has already installed a frame assembly calling for three hinges, it will 
follow that expensive, disruptive work will be necessary to remove the 
installed frame assembly and replace it with another, of alternate 
configuration. Thus, the need will be seen to exist for a frame assembly 
permitting of ready alteration of the strike and hinge provision without 
requiring disassembly or modification of the remainder of an installed 
frame assembly. All the more flexibility will be provided when the 
foregoing feature is combined with the adjustability of the frame elements 
to accommodate walls of different thicknesses, along with replaceable door 
stop and trim cap members. 
DESCRIPTION OF THE RELATED ART 
The broad concept of adjustable door frames comprising a plurality of 
components is shown in U.S. Pat. No. 3,420,003 issued to Cline and which 
includes outer and inner strips slidably interfitting to accommodate 
varying wall thicknesses and wherein the edge of one strip is slidable 
beneath a stop element forming an integral part of the other strip. U.S. 
Pat. No. 3,609,928 issued to Mock illustrates an example of a jamb 
assembly having both trim elements and a door stop comprising separate 
components. In this instance, the entire Mock jamb assembly components 
comprise plastic members and the separate components are snap fitted upon 
a unitary base member. At least one embodiment in U.S. Pat. No. 4,589,229 
issued to Warren illustrates the provision of a distinct door stop member 
in an otherwise two-piece adjustable jamb assembly. In this referenced 
example, the stop member comprises a U-shaped member cooperating with a 
tongue projecting from one piece of the assembly. The unique combination 
as advanced by the present invention is not seen to be suggested by any 
combination of the above prior art. 
SUMMARY OF THE INVENTION 
By the present invention, an improved door frame assembly is provided and 
wherein a removable and replaceable strike or hinge provision is 
available, along with a removable door stop. The main frame element may 
comprise a unitary member providing both inside and outside channels with 
respective integral trim elements or, a pair of channel members 
interfitting with one another to accommodate walls of varying thicknesses. 
Optionally, removable trim elements may be provided. With the above 
construction, various configurations of either the hinge or strike 
provision may be mounted upon a channel member, even after the channel 
members have been installed within the roughened door opening. In this 
manner, the hinge and strike provisions may be truly customized according 
to the dictates of each and every door installation. Additionally, at any 
future time, a different door calling for dissimilar hinge and/or strike 
provisions, may be readily accommodated without having to replace the 
entire frame assembly and merely by substituting another hinge and/or 
strike member. 
Accordingly one of the objects of the present invention is to provide an 
improved door frame assembly including inner and outer channels slidably 
adjustable to accommodate varying wall thicknesses with one channel 
removably receiving a snap-fitting plate serving as a replaceable hinge or 
strike provision. 
Another object of the present invention is to provide an improved door 
frame assembly including a pair of laterally adjustable channels each 
having an edge member and with one channel provided with snap-fitting 
means removably receiving a replaceable door stop. 
A further object of the present invention is to provide an improved door 
frame assembly including adjustable inner and outer channels each having 
an edge member provided with snap-fitting means cooperating with 
replaceable trim elements. 
Still another object of the present invention is to provide an improved 
door frame assembly including a unitary channel having a stepped portion 
removably receiving a replaceable hinge or strike plate adjacent a 
removable door stop member. 
With these and other objects in view which will more readily appear as the 
nature of the invention is better understood, the invention consists in 
the novel combination and assembly of parts hereinafter more fully 
described, illustrated and claimed with reference being made to the 
attached drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
Referring now to the drawings, the various views will be understood to 
depict alternative door frame assemblies which may be configured to 
accommodate walls of varying thicknesses. Each embodiment comprises a 
plurality of elongated components, preferably formed from sheet metal 
stock. As is well known in this art, such frames are employed along three 
sides of a door opening and define a hinge, strike and header channel when 
installed. In all of the disclosed embodiments, a removable door stop as 
well as a removable hinge/strike plate are provided. In this manner, any 
one of the illustrated frame assemblies may be utilized to enclose the 
three sides of a door opening, with the means permitting attachment of the 
hinge/strike plate permitting the installation of a customized strike 
plate within the channel along one side of the opening as well as a 
customized hinge plate within the same type of channel as applied along 
the opposite side of the opening. In any case, the same channel 
construction will be used to form the header channel and wherein an 
imperforate hinge/strike plate is used. 
FIG. 1 depicts a door frame assembly A which is configured to accommodate a 
specific wall thickness and includes a primary frame element 10 and stud 
12, each of which comprises a fixed or unitary member having structural 
formations adapted to cooperate with one another. The frame element 10 
includes an outside channel 14 joined to an inside channel 16. The inner 
edge 18 of the outside channel is connected to the inner edge 20 of the 
inside channel by means of an intermediate offset wall 22 which will be 
seen to be disposed normal to the plane of the faces 24,26 of the channels 
14, 16 respectively. 
A replaceable door stop member 28 is adapted to be snap-fitted upon the 
medial area of the frame element 10, adjacent the inner edge 18 of the 
outside channel face 24. The stop member includes an outer surface 30 
bounded by an outer wall 32 and inner wall 34 the latter of which will be 
seen to be formed with a recess 36 adapted to receive and retain a 
removable bumper or cushion strip 38. The stop 28 is snap-fittedly 
attached to the frame element 10 by the interaction of hook elements 40 
adjacent the free edges of the stop walls 32,34 and which engage mating 
recesses on a pair of projections 42,44 extending from the channel face 
24. With this arrangement, a stop member 28 may be easily replaced should 
it become damaged in use and without the necessity of tearing out an 
entire channel assembly. Likewise, various sizes of stops may be assembled 
with any one frame element so as to accommodate doors of alternate 
weights. 
The offset or displacement of the plane of the inside channel face 26 will 
be seen to provide a longitudinal cavity or recess 46 between the offset 
wall 22 and the face 48 of the inside trim section 50. This cavity 46 
serves to accommodate mounting means providing for the snap-fitted 
attachment of a hinge or strike plate 52. The planar face 54 of this plate 
is adapted to fully overlie the channel cavity 46 and includes an inner 
edge 56 abutting the inner edge 18 of the outside channel 14 and an outer 
edge 58 mating with the corner edge 60 of the inside trim face 48. The 
plate is retained in the installed position, by means of a pair of 
preferably continuous hook elements 62,64 engageable with mating 
projections or ledges 66,68 extending into the cavity 46 of the inside 
channel 16. Flush disposition of the installed plate 52 is assured as its 
inside surface 70 flushly abuts and snap-fits against the pair of opposed 
ledges 66,68 extending respectively from the offset wall 22 and trim 
section face 48. 
With the above described construction it will be appreciated that with any 
one frame element 10, the plate 52 may be utilized to provide either a 
strike or hinge provision. The specifics of such provisions need not be 
dwelled upon herein since numerous hinge and strike provisions are well 
known to those skilled in this art and the present invention involves the 
inclusion of a hinge and strike plate which is a separate member, 
snap-fittingly attached, regardless of the form or attachment of hinges or 
means adapted to guide a lock bolt during opening and closing of the 
associated door. 
Completing the structure of the frame element 10 is an outside trim section 
76 having a face 78 joined to the outside channel 14 at its corner edge 
80. Each of the two trim sections 50,76 are provided with an inturned lip 
82 at their free edge and which are adapted to engage an underlying wall 
surface (not shown). The attachment of the door frame assembly A is 
accomplished by affixing a portion of the frame element 10 to underlying 
structure defining the door opening. Usually, this structure comprises a 
stud and the stud 12 as shown in FIG. 1 will be seen to include a stepped 
outer face or web 84 from which extend a pair of spaced apart flanges 
86,88. The fixation of the frame element 10 is most readily achieved by 
the application of suitable fasteners, such as sheet metal screws 90 and 
which are driven through the frame element and into the underlying stud 
web 84. Such fasteners will be seen to be completely masked from view, 
upon the attachment of the stop 28 and hinge/strike plate 52. 
The door frame assembly B of FIG. 2 employs the removable and replaceable 
stop and plate features of the above described frame assembly A and adds 
an adjustability capability in order to accommodate various wall 
thicknesses with but one primary frame element 100. In this instance, the 
outside channel 102 will be seen to comprise a member that is separate 
from the inside channel 104 and the mounting projections 106,108 for 
attachment of the stop member 110 extend from the first face 112 of the 
inside channel 104. The second face 114 of the inside channel functions in 
cooperation with a trim section 50 and hinge/strike plate 52 in a manner 
similar to that as explained with respect to the FIG. 1 assembly. 
Likewise, an outside trim section 76 extends from the corner edge 116 of 
the face 118 of the outside channel 102. 
The inner edge 120 of the outside channel face 118 will be seen to be 
disposed beneath the inside channel first face 112 and with at least its 
distal portion located within a slot as formed by a flange 122 projecting 
from the offset wall 124. With this construction, various wall thicknesses 
may be accommodated by laterally displacing the two channels 102,104 
relative one another as reflected by the broken lines in FIG. 2. The frame 
assembly B may be affixed to either a wooden stud 126 or a metal one as 
with the stud 12 of FIG. 1 and again, the assembly may be secured as by 
fasteners 90 passing through the single or double layers of channel 
elements and into the stud. The stud 126 preferably includes an outer face 
127 mating with the configuration of the offset channel faces 114,118. 
The door frame assembly C of FIG. 3 depicts a further modification of the 
adjustable frame assembly B shown in FIG. 2 and wherein removable trim 
caps 300 are adapted to be snap-fitted upon trim sections 302,304 
extending from both the inside channel 306 and outside channel 308. This 
attachment is accomplished by means of pairs of hook strips 310 projecting 
from each trim section 302,304 and engageable with catch elements 312 on 
the side walls 314 of the trim caps 300. 
From the foregoing, it will be appreciated that ready means has been 
provided whereby both the strike and hinge provisions of a door frame 
assembly may be quickly selected or subsequently altered, through the 
attachment or replacement of a plate member which is snap-fitted into a 
position overlying the inside channel of the primary frame element. 
Likewise, the stop member comprises a separate element that is snap-fitted 
into place while, the frame element may comprise two separate channel 
elements with overlying portions permitting accommodation of walls of 
varying thicknesses. 
It is to be understood that the present invention is not limited to the 
sole embodiments described above, but encompasses any and all embodiments 
within the scope of the following claims.