Abstract:
A door frame assembly and method of mounting the same, which does not require the use of exterior fasteners to secure members of the door frame assembly to a support frame in a doorway of a building. A connecting member is securable to a support frame member. A doorjamb member is attachable to the connecting member. A trim member is attachable to the connecting member and the door jamb member. The connecting combinations between the connecting member, the door jamb member and the trim member are such that once the door frame assembly is fully assembled, the door jamb member and the trim member cannot be disconnected from the support frame member absent an intervening force.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to door frame assemblies for use in doorways of building structures, and methods of mounting the same. 
     BACKGROUND OF THE INVENTION 
     Door frame assemblies have been utilized in the building industry for many years. Up until relatively recently, door frame assemblies were almost always constructed of a wood-based members. Although wood is a generally acceptable material, the use of wood has several disadvantages. For example, wood is subject to impact damage, such as denting or splintering upon contact. Wood also has a tendency to deteriorate upon exposure to water, insects, sunlight and various other undesirable influences. In addition, wood is a relatively expensive raw material, and requires labor intensive assembly and finish work. More recently, aluminum, steel and vinyl cladding have been used to cover exterior wood-based door frame assemblies to protect the wood structure from exposure to such noted undesirable influences. However, such cladding simply masks the shortcomings of the existing wood door frame assemblies. Moreover, cladding generally requires time consuming installation, thereby increasing the associated overall cost of the door frame assembly. Even more recently, door frame assemblies manufactured from synthetic materials and composite materials have been produced to replace or compliment wood-based door frame assemblies. However, door frame assemblies made from such synthetic and composite materials often lack the structural integrity of wood-based door assemblies, thereby requiring the use of reinforcing means or additional structural supporting devices. 
     Consumer demand for economical, low maintenance, yet reliable and aesthetically pleasing, door frame assemblies continues to increase year after year. One way to cut costs associated with building and assembling door frame assemblies is to reduce material costs. Another way to cut costs associated with building and assembling door frame assemblies is to reduce labor time. Thus, there exists a need for a door frame assembly which is economical to manufacture and assemble, which is structurally sound and durable, and which provides a desirable appearance. 
     SUMMARY OF THE INVENTION 
     In accordance with the above-described needs and other needs, the present invention solves the noted problems and other problems of the prior art. The present invention provides a door frame assembly and method of mounting the same, which eliminates or minimizes the use of exterior fasteners to secure members of the door frame assembly to a support frame in a doorway of a building. In a preferred embodiment, door jamb members and trim members of the door frame assembly are each made of a solid, single, unitary piece of extruded polyvinyl chloride material. 
     The invention includes a connecting member which is securable to a support frame member in a door way of a building. A door jamb member is attachable to the connecting member. A trim member is also attachable to the connecting member. The connecting member and the door jamb member have a male/female relationship that allows the door jamb member to be attached to the connecting member without the use of nails, screws or other additional mechanical means. Likewise, the connecting member and the trim member also have a male/female relationship that allows the trim member to be attached to the connecting member without the use of nails, screws or other additional mechanical means. Preferably, the door jam member and the trim member include a male/female relationship, so that the trim member can also be secured to the door jamb member. The connecting relationships between the connecting member, the door jamb member and the trim member, eliminate the requirement for exterior fasteners to secure the door jamb member and the trim member to the associated support frame member in the doorway of the building. 
     Other features and advantages of the present invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings in which like numerals are used to designate like features. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a fragmentary, perspective view of a doorway of a building in which the present invention is employed. 
     FIG. 2 is a fragmentary, exploded perspective view of a door frame assembly according to the present invention. 
     FIG. 3 is a fragmentary, sectional perspective view of an assembled door frame assembly positioned in a doorway, such as the doorway of FIG. 1, according to one aspect of the present invention. 
     FIG. 4 is a fragmentary, sectional perspective view of an assembled door frame assembly positioned in a doorway, such as the doorway of FIG. 1, according to one aspect of the present invention. 
     FIG. 5 is a fragmentary, cross-sectional view of an assembled door frame assembly positioned in a doorway, such as the doorway of FIG. 1, according to one aspect of the present invention. 
    
    
     Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. The use of “consisting of” herein is meant to encompass only the items listed thereafter and the equivalents thereof. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Illustrated in FIG. 1 is a doorway  10  of a building in which the present invention is employed. It being understood that the present invention is capable of use in doorways other than that illustrated in FIG. 1, and that the doorway  10  is merely shown and described as an example of one such doorway. Door frame assemblies  100  (FIGS.  2 - 3 ),  100 ′ (FIG. 4) and  100 ″ (FIG. 5) of the present invention support a door  14  (see also, FIGS. 3-4) which is movable between open and closed positions. 
     With continued reference to FIG. 1, a first vertical door jamb member  18  and a spaced apart, substantially identical, second vertical door jamb member (not shown) extend upwardly from a sill or threshold  22 . A head door jamb member (not shown) extends across, and is integral with, the top edges of the vertical door jamb members. The head door jamb member is practically the same as the vertical door jamb members, except the length of the head door jamb member is shorter than the length of the vertical door jamb members. Thus, reference to one door jamb member can be appropriately viewed as reference to the other door jamb members. A first vertical trim member  26 , a second, substantially identical vertical trim member  30  and head trim member  34  are positioned adjacent to the associated doorjamb members. The head trim member  34  is practically the same as the vertical trim members, except the length of the head trim member is shorter than the length of the vertical trim members. Thus, reference to one trim member can be appropriately viewed as reference to the other trim members. 
     Although not shown in FIG. 1, but as can be appreciated, beneath the door jamb members and the trim members is a support frame. The door opening of the doorway  10  is originally defined by the support frame which includes a top wall or top frame member, a pair of opposed side walls or side frame members, and the bottom sill or threshold  22 . The door jamb members and the trim members are attached to the support frame in a manner which will be more fully explained below. As can at least partially be observed in FIG. 1, and according to the principles of the present invention, no external fasteners are needed to attach the door jamb members and the trim members to the frame walls of the support frame. Preferably, the door jamb members and the trim members are each made of a solid, single, unitary piece of extruded polyvinyl chloride (PVC) material, but can be made of multiple pieces and of different material. PVC is less susceptible to impact damage than other materials. PVC is also water proof, UV-stable, corrosion resistant, paintable if desired, resistant to mold, mildew or dirt build-up, and resistant to insect infestation. PVC is generally a maintenance free material. 
     FIG. 2 illustrates fragmentary portions of the components of the door frame assembly  100  according to one aspect of the present invention. Shown is the door jamb member  18 , the trim member  26 , and an associated connecting member or fin  38 , it being understood that similar door jamb members, trim members and connecting fins are utilized around an entire doorway. A conventional weather stripping  42 , which forms no part of the present invention, is appropriately secured to the door jamb member  18  to provide a seal between the door  14  and the door jamb member  18  as commonly understood (see FIGS.  3 - 4 ). 
     The door jamb member  18  includes a groove  46  in one side  48  thereof; the groove  46  preferably completely extends from the top edge  50  of the door jamb member  18  to the bottom edge  54  (FIG. 1) of the door jamb member  18 . It is noted that the top edge  50  and the bottom edge  54  of the door jamb member  18  can be cut or mitered as may be needed (see, e.g., FIG.  1 ). The door jamb member  18  also includes a projecting member  58  on another side  62  thereof; the projecting member  58  preferably completely extends from the top edge  50  of the door jam member  18  to the bottom edge  54  of the door jamb member  18 . The doorjamb member  18  further preferably includes a plurality of recesses  66  in side  48  which abuts a side support frame member  70  (FIGS. 3-5) upon installation. The recesses  66  can be of different shapes and sizes, but the recesses preferably completely extend from the top edge  50  of the door jamb member  18  to the bottom edge  54  of the door jamb member  18 . The recesses  66  add strength and rigidity to the doorjamb member  18  when the doorjamb member  18  is attached to the side frame member  70 . 
     The trim member  26  includes a groove  74  in one side  78  thereof; the groove  74  preferably completely extends from the top edge  80  of the trim member  26  to the bottom edge  82  (FIG. 1) of the trim member  26 . It is noted that the top edge  80  and the bottom edge  82  of the trim member  26  can be cut or mitered as may be needed (see, e.g., FIG.  1 ). The trim member  26  also includes a slot  84  in side  78 ; the slot  84  preferably completely extends from the top edge  80  of the trim member  26  to the bottom edge  82  of the trim member  26 . The trim member  26  further preferably includes a recess  86  in side  78  which faces the side support frame member  70  (FIGS. 3-5) upon installation. Recess  86  can be of different shapes and sizes, but the recess  86  preferably completely extends from the top edge  80  of the trim member  26  to the bottom edge  82  of the trim member  26 . Recess  86  adds strength and rigidity to the trim member  26  when the trim member  26  is properly attached to the support frame. 
     The connecting member or fin  38  includes a first elongated leg  88  and a second elongated leg  90  which are arranged to have an “L” shaped cross-section. A locating member  92  projects outwardly from and perpendicular to leg  88 ; the locating member  92  preferably completely extends from the top edge  94  of the connecting fin  38  to the bottom edge (not shown) of the connecting fin  38 . A locating member  96  projects outwardly from and perpendicular to leg  90 ; the locating member  96  preferably completely extends from the top edge  94  of the connecting fin  38  to the bottom edge of the connecting fin  38 . It is noted that the top edge  94  and the bottom edge of the connecting fin  38  can be cut or mitered as may be needed. Preferably, the overall length of the connecting fin  38  corresponds with the overall length of the associated door jamb member  18  and the associated trim member  26 . Preferably, the connecting fin  38  is a single, unitary piece of extruded aluminum, but can be made of multiple pieces and of different material. 
     FIG. 3, in conjunction with FIG. 2, illustrates the door frame assembly  100  mounted on the support frame or side support member  70 . The connecting fin  38  is secured to a wall member or the side support member  70  with nails, screws  97  or other fastening means (see FIG.  2 ). The connecting fin  38  can include a plurality of apertures  98  to receive the appropriate fastening means. 
     The doorjamb member  18  is then secured to the connecting fin  38 . The groove  46  of the door jamb member  18  receives the locating member  92  of the connecting fin  38 . The groove  46  and the locating member  92  are designed to provide an interference fit, a snap-fit connection or the like, such that once the locating member  92  mates with the groove  46 , the door jamb member  18  cannot separate from the connecting fin  38  absent an outside intervening force. FIG. 5 illustrates one such alternative mating relationship, wherein the locating member  92 ′ is provided with a ribbed end. Accordingly, because the connecting fin  38  is firmly secured to the support frame or side support member  70 , the door jamb member  18  is secured to the support frame or side support member  70 . The door jamb member  18  can be further secured to the support frame or side support member  70  with nails, screws  99  (FIG. 2) or other fastening means for added stability, if so desired. Door jamb member  18  can include a plurality of apertures  95  to receive the appropriate fastening means. It is noted that the exterior fasteners, if utilized, are generally hidden behind a side edge of door  14  (see FIGS.  3 - 4 ), so as not to generally require maintenance. 
     The trim member  26  is then secured to the connecting fin  38 . The groove  74  of the trim member  26  receives the locating member  96  of the connecting fin  38 . The groove  74  and the locating member  96  are designed to provide an interference fit, a snap-fit connection or the like, such that once the locating member  96  mates with the groove  74 , the trim member  26  cannot separate from the connecting fin  38  absent an outside intervening force. FIG. 5 illustrates one such alternative mating relationship, wherein the locating member  96 ′ is provided with a ribbed end. Accordingly, because the connecting fin  38  is firmly secured to the support frame or side support member  70 , the trim member  26  is secured to the support frame or side support member  70 . The trim member  26  is further secured to the support frame or side support member  70  and the door jamb member  18  by positioning the projecting member  58  of the door jamb member  18  into the slot  84  of the trim member  26 . The connecting joint between the projecting member  58  and the slot  84  can be an interference fit, a dovetail joint, a snap-fit connection or any other suitable joint. 
     Having described the structural components and assembly of the door frame assembly  100 , it should be readily apparent that the door frame assembly  100  is designed in such a way that the members of the door frame assembly cannot pull away from the support frame absent an outside intervening force. The use of connecting fins in combination with the associated door jamb members and trim members eliminates the required use of external fasteners, as is the case with prior door assemblies. 
     FIG. 4 illustrates a slight modification of the door frame assembly  100  shown in FIGS. 2-3. Door frame assembly  100 ′ includes an extension door jamb member  18 ′. Door frame assembly  100 ′ accommodates deeper door jamb widths associated with support frames constructed of a 2″×6″ construction. Extension door jamb member  18 ′ is generally similar to door jamb member  18 . However, as shown, extension door jamb member  18 ′ includes a slot which is similar to slot  84  of trim member  26  for assembly purposes. 
     As described, the door frame assembly according to the present invention is economical to manufacture, assemble and maintain, yet is also of a reliable construction and aesthetically pleasing. 
     The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention in the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings in skill or knowledge of the relevant art, are within the scope of the present invention. The embodiments described herein are further intended to explain the best modes known for practicing the invention and to enable others skilled in the art to utilize the invention as such, or other embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims are to be construed to include alternative embodiments to the extent permitted by the prior art. 
     Various features of the invention are set forth in the following claims.