Abstract:
An apparatus and method for temporarily mounting a side rail such as a z-bar during installation of a door assembly. The apparatus includes a mounting structure cooperating with a fastener to accurately position the side rail at a location on a structural member such as a door jamb. In the case of hinge-side side rails, the side rail may be aligned without the door attached thereto while establishing the location for the fastener. The mounting structure may aid in the proper placement of the fastener in the structural member. Once the fastener is in place, the side rail can be removed from the structural member without removing the fastener. The door may then be attached to the side rail to form a door/side rail assembly. The door/side rail assembly is then temporarily engaged with the fastener for accurate positioning while the side rail is affixed to the structural member.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/003,344, filed Nov. 16, 2007, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to assemblies for doors. More particularly, the present invention relates to structures and methods for installing side rails for door assemblies, such as z-bars. 
     BACKGROUND OF THE INVENTION 
     A door assembly, such as a storm door, often involves the use of what is commonly referred to as a “z-bar.” The z-bars are typically formed to mount the door assembly to the jambs or exterior trim of the entry door. Normally there are two z-bars in such an installation: a hinge-side z-bar and a latch-side z-bar. The hinge-side z-bar is so named because it accommodates hinges for pivotal mounting of the door. The latch-side z-bar is so named because it is located adjacent the latch side of the door and may serve as part of a system to latch the door in a closed position. 
     Mounting a door having a z-bar or z-bar assembly, particularly the hinge-side z-bar with the door attached, can be problematic. The hinge-side z-bar and door may be placed in the opening of the door casing, and the hinge-side z-bar attached to the appropriate jamb. However, the combination of z-bar and attached door may prove to be unwieldy, particularly for an inexperienced installer, resulting in misalignment. Alternatively, the z-bar may be detached from the door and mounted to the casing, but this necessitates either mounting the door to the hinges thereafter with the z-bar in place, or dismounting the z-bar and accompanying fasteners, reattaching the z-bar to the door, and then realigning the z-bar in the previous mounting arrangement and with the door present. These scenarios may require two people to mount the door properly. 
     There is a need in the industry for a z-bar assembly that is configured for easier installment of the door within the casing. 
     SUMMARY OF THE INVENTION 
     Various embodiments of the invention provide for a mounting structure within, on or integral to a door side rail such as a z-bar that cooperates with a fastener or fasteners to hold the side rail in place temporarily while the side rail is permanently affixed to a door opening. The mounting structure may serve as a guide or enable the placement of guide marks for accurate positioning of a fastener that temporarily holds the side rail/door assembly (hinged door assembly) within the door opening. The side rail may further be configured to enable release from the structural member without removing the fastener. The mounting structure enables a single, inexperienced installer to accurately position the hinged door assembly in the door opening. 
     In one embodiment, a method is disclosed wherein the user positions a “doorless” hinge-size side rail (that is, a hinge-side side rail that does not have a door attached thereto) in a desired orientation on a door opening frame member such as a door jamb. The hinge-side side rail may then be used to guide or mark a location for placement of a fastener. The fastener may be installed so that the hinge-side side rail is captured but not held fast by the fastener, thus enabling removal of the hinge-size side rail while the fastener remains in place. The hinge-side side rail may then be removed and a door attached thereto. The hinged door assembly may then be mounted to the fastener, which holds the hinged door assembly temporarily in place while the side rail is permanently affixed to the door opening frame member. 
     Structurally, the mounting structure may include a through-hole or aperture of various shapes such as a round, a square, a triangle, a diamond, a keyhole or any other geometry that enables passage of a fastener head therethrough. In some embodiments, the mounting structure may include a hanger structure affixed to the side rail. The hanger structure may include projections that may be used to form indentations on the door opening frame member for location of the fastener with side rail removed from the door opening frame member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a partial perspective view of a hinge-side z-bar and door; 
         FIGS. 2A and 2B  are perspective views of the hinge-side z-bar of  FIG. 1  with the door removed; 
         FIG. 3  is a top view of a standard z-bar; 
         FIG. 4  is a partial plan view of a z-bar having lateral slots in an embodiment of the invention; 
         FIG. 5  is an enlarged partial view of the through slot of  FIG. 4 ; 
         FIG. 6  is the enlarged partial view of  FIG. 4  with a fastener passing therethrough; 
         FIG. 7  is the enlarged partial view of  FIG. 4  with the fastener aligned for removal of the z-bar; 
         FIG. 8  is a partial sectional view of  FIG. 6 ; 
         FIG. 9  is a partial plan view of a z-bar having longitudinal slots in an embodiment of the invention; 
         FIG. 10  is an enlarged partial view of the through slot of  FIG. 9 ; 
         FIG. 11  is the enlarged partial view of  FIG. 9  with a fastener passing therethrough; 
         FIG. 12  is the enlarged partial view of  FIG. 9  with the fastener aligned for removal of the z-bar; 
         FIG. 13  is a partial perspective view of a z-bar aligned for mounting within a casing in an embodiment of the invention; 
         FIG. 14  is the aligned z-bar of  FIG. 13  with a fastener passing through the through slot; 
         FIG. 15  is the partial perspective view of  FIG. 13  with the z-bar removed; 
         FIGS. 16A through 16D  depict different shaped through-slots in various embodiments of the invention; 
         FIG. 17  is a partial view of a hinge-side z-bar with a hanger plate in an embodiment of the invention; and 
         FIGS. 18 through 20  depict various hanger plates in isolation in various embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1 ,  2 A and  2 B, a standard hinged door assembly  30  that includes a door  32  operatively coupled with a hinge-side z-bar assembly  34  is depicted. The hinge-side z-bar assembly  34  includes a z-bar  38  and a plurality of hinge members  40  (only one depicted). The hinged door assembly  30  is mounted to a structural member  42  such as a door jamb. 
     The z-bar  38  may be characterized as having an outward-facing surface  50  that faces away from the structural member  42  ( FIG. 2A ), as well as an inward-facing surface  52  that faces toward the structural member  42  ( FIG. 2B ). The z-bar  38  may also be characterized as having a flange portion  60 , a barrel portion  62 , a web portion  64  and a projecting portion  66 . 
     Mounting the standard hinged door assembly  30  can be problematic, particularly for one who is inexperienced in the installation of doors. Generally, the hinged door assembly  30  is placed in the opening of the door casing, and the hinge-side z-bar assembly  34  attached to the structural member  42 . However, the hinged door assembly  30  may be unwieldy, resulting in misalignment. Alternatively, the hinge-side z-bar assembly  34  may be detached from the door  32  and mounted to the structural member  42 , but this necessitates either mounting the door  32  to the hinge members  40  thereafter with the z-bar assembly  34  in place, or dismounting the z-bar assembly  34  and accompanying fasteners, reattaching the z-bar assembly  34  to the door  32 , and then realigning the z-bar assembly  34  in the previous mounting arrangement and with the door  32  mounted thereto. These scenarios may be time consuming and may require two people to mount the door properly. 
     Referring to  FIG. 3 , a standard z-bar  70  is depicted in isolation to more clearly identify the components, which are numbered the same as for the z-bar  38  of  FIGS. 1 ,  2 A and  2 B. The flange portion  60  generally provides registration of the z-bar on the outward-facing surface of the structural member  42 , and may be secured to the outward-facing surface by gluing or by driving fasteners through the flange portion. The barrel portion  62  may provide structure for mounting the barrel or knuckle portion of a hinge member on hinge-side z-bars, or simply provide a uniform or symmetrical complimentary appearance for latch-side z-bars. The web portion  64  typically extends along a face of the structural member to define the depth of the z-bar. The projecting portion  66  may serve as a registration for the door  32  to seat against, and typically houses weather stripping (not depicted) for insulation purposes. Additional details regarding z-bars are provided at U.S. Patent Application Publication No. 2008/0163554, assigned to the assignee of the present application, the disclosure of which is incorporated by reference herein except for express definitions contained therein. 
     While the figures and much of the present application discussion is directed to applications that utilize z-bars, it is understood that the invention is not limited to implementation with z-bars. More generally, the invention can also be implemented with what is hereinafter referred to as “side rails” that mount to a side or corner of a structural member and may or may not include all the features of a z-bar. For example, a side rail for use on the latch side of a door may be void of a barrel portion, as no hinge is to be supported thereon. Other side rails may not include a flange portion, relying instead, for example, on mounting the side-rail with fasteners that pass through or are otherwise coupled with the web portion  64  for attachment. Still other side rails may cooperate with other structures for registration of the door when in the closed position, thereby not requiring or including a projecting portion. Accordingly, a “side rail” is a device that operatively couples with a door to provide either a hinge-side connection or a latch-side connection with the door, and may be void of the various aspects that are not required for the hinge-side or latch-side functionality. 
     Referring to  FIGS. 4 through 8 , a slotted z-bar  180  having a longitudinal axis  181 , an overall length  182  and a plurality of hinge members  184  operatively coupled thereto is depicted in an embodiment of the invention. In this embodiment, the z-bar  180  includes a first through slot  186  formed on the web portion  64  of the z-bar  180  proximate a first end  188  of the z-bar  180 , as well as a second through slot  190  proximate a second end  192 . The through slots  186 ,  190  may be located a distance  194  from the respective end  188 ,  192  and a distance  196  from the hinge member  184  nearest the respective end  188 ,  192 . While the  FIG. 4  configuration depicts the through slots  186  and  190  as proximate the ends  188  and  189 , respectively, the slots may be located anywhere on the z-bar  180  (e.g. between the hinge members  184 , not depicted). 
     The through slots  186 ,  190  may be characterized as having a major length  197  and a varying width, and may each be defined by the confluence of a large opening  198  that necks down to and is common with a smaller opening  200 . A narrow portion  202  may be defined between the large opening  198  and the smaller opening  200 . The large opening  198  may be sized larger than the diameter of a head  204  of a fastener  205 , while the smaller opening  200  and narrow portion  202  are smaller than the diameter of the head  204 . The through slots  186 ,  190  may be arranged so that the major length  197  is substantially perpendicular to the longitudinal axis  181 . 
     The fastener  205  is further characterized as having a shaft portion  206  and may be any fastener available to the artisan, such as a cap screw with a pan head, flat head or hex head screw, or a nail. Headless fasteners may also be utilized and may implement retention hardware such as internal tooth retainers. Shaft portions that cooperate with removable head portions such as wing nuts may also be implemented. 
     In operation, the large opening  188  enables the head  204  to pass therethrough, whereas the smaller opening  200  does not. As depicted in  FIG. 6 , the z-bar  180  may be affixed to the structural member  42  by placing the z-bar  180  in the desired location and installing the fastener through the smaller opening  200  and into the structural member  42  so that the head  204  is immediately adjacent or over a perimeter portion  207  about the smaller opening  200  ( FIG. 8 ). By this structure and method, the z-bar  180  is used to locate the mounting position of the fastener  205 . The head  204  may clear the structural member  42  enough to enable the z-bar  180  to slide freely on the structural member, or with slight contact to generate some friction. The z-bar  180  may then be slid in a lateral direction  208  (i.e. a direction substantially perpendicular to the longitudinal axis  181 ) until the head  204  is located in the large opening  198 , as depicted in  FIG. 7 . The z-bar  180  may then be pulled away from the surface so that the large opening  198  passes by the perimeter of the head  204 . 
     Referring to  FIGS. 9 through 12 , an alternative embodiment of a slotted z-bar  180   a  is depicted in an embodiment of the invention. The slotted z-bar  180   a  as depicted is similar in many respects to the slotted z-bar  180 , with one notable exception: the slots  186   a  and  190   a  are arranged with the major length  197  substantially parallel to the longitudinal axis  181 . In this configuration, the z-bar  180   a  is slid in a parallel direction  209  with respect to the longitudinal axis to align the head  204  with the large opening  198 . 
     Structural embodiments of the invention that include two structures for hanging (e.g. through slots  186   a  and  190   a ), one each proximate the ends  188 ,  192 , may be suitable for mounting on either a left or a right door jamb. 
     Referring to  FIGS. 13 through 15 , a method of installing the z-bar  180  is depicted in an embodiment of the invention. The z-bar  180  may be placed on the structural member  42  so that the end  192  registers against a header portion  210  of a door casing  211 , the casing  211  defining an opening  212  ( FIG. 13 ). The z-bar  180  may be oriented so that the smaller opening  200  is oriented in closer proximity to an outer face  214  of the structural member  42  than is the large opening  198 . The depth of the z-bar  180  within the opening may be established by registering the flange portion  60  against the outer face of the structural member  42 . The fastener  205  may be aligned and installed to pass through smaller opening  200  of the through slot  186 . Initially, the fastener  205  may be threaded into the structural member  42  so that the head  204  is brought into non-clamping contact with the z-bar  180 . Herein, reference to “non-clamping contact” refers to intermittent or slight contact that generates only a low frictional force that releasably holds the z-bar  180  in contact with the structural member  42 . The z-bar  180  may be brought forward and until the large opening  198  is aligned with the fastener  205 . The z-bar  180  may then be moved clear of the fastener  205  and removed from the opening  212 . The fastener  205  may be left in the structural member  42  after removal of the z-bar  180  ( FIG. 15 ). 
     The z-bar  180  may be attached to the door  32  remote from the opening  212  before lifting the door  32  with z-bar  180  back into the opening  212  (not depicted). The large opening  198  of the through slot  186  may then be aligned with and slid over the fastener  205  in the structural member  42 , and the z-bar  180  registered against the outer face of the structural member  42 . With the added weight of the door, the z-bar may settle a fraction of an inch (e.g. 1/16-in.) thereby enabling room for a drip cap to be installed on the underside of the header portion  210 . The door  32  is now aligned at the proper height and depth within the opening, and may be secured in place by tightening the fastener  205  against the z-bar  180  and/or by installing additional fasteners through the z-bar  180  (not depicted). 
     The method above eliminates the need for an installer simultaneously run fasteners through the z-bar while holding the door  32  in proper alignment. Instead, the fastener  205  serves as an alignment device and a holding device that holds the door  32  and z-bar  180  in place while the z-bar  180  is secured permanently in place. 
     Installation of the z-bar  180   a  ( FIGS. 9 through 12 ) with slots  186   a ,  190   a  that are oriented with the major length  197  parallel to the longitudinal axis  181  may be similar to the procedures outlined above. It is noted that longitudinally-oriented slots may require additional space between the end of the z-bar (e.g. end  192 ) and the header portion  210  to enable the installer to lift the z-bar  180   a  for release. This additional space can expose a portion of the structural member  42  that may otherwise be covered by the z-bar. The exposed portion of the structural member  42  may be covered using a z-bar extender, such as disclosed in U.S. Patent Application No. 60/875,480, assigned to the assignee of the present application and included herein as an Appendix. 
     The use of through slots  186 ,  190  or other through-apertures may also be utilized on the flange portion  60  for the same effect (not depicted). Where laterally oriented through slots  186 ,  190  are utilized, the through slots  186 ,  190  may be formed on the front face of the flange portion  60  with the smaller opening  200  oriented toward the opening  212 . A z-bar so configured could be slid toward the center of the opening  212  for release of the z-bar. 
     Referring to  FIGS. 16A through 16D , alternative shapes to the generally keyhole shaped through-slots  186 ,  190  and  186   a ,  190   a  are presented in other embodiments of the invention. Viable shapes include, but are not limited to, a round  220  or a polygonal shape such as a square  222 , a triangle  224  or a diamond  226  ( FIGS. 16A through 16D , respectively) or any other geometry that enables passage of a fastener head therethrough. Example longitudinal axes  181  are superimposed on the shapes as well. A common factor with these geometries is that the head  204  of the fastener  205  can pass through a portion of the aperture. 
     Each of the  FIGS. 16A through 16D  depict the fastener  205  centered at a first position  232  (solid lines) that is justified to one side of the respective through-aperture when the z-bar  180  is in an aligned or final position. Alternatively, the fastener  205  can be centered at a second position  234  (phantom line), also at an aligned or final position, that is justified at the top of the respective through-aperture. Each of the first positions  232  enable release of the z-bar  180  by moving the z-bar laterally, i.e. in a direction perpendicular to the longitudinal axis  181 . By contrast, each of the alternative positions  234  enable release of the z-bar  180  by moving the z-bar longitudinally, i.e. in a direction parallel to the longitudinal axis  181 . 
     Functionally, the through-apertures of  FIGS. 16A through 16D  may be utilized in ways similar to the through-slots  186 ,  190  and  186   a ,  190   a . For fasteners in the first position  232 , the z-bar may be used to guide placement of the fastener  205  and then be released by a lateral or horizontal movement, akin to the description attendant  FIGS. 4 through 8 . For fasteners in the second position  234 , the z-bar can also be used to guide placement of the fastener  205 , but released by a longitudinal or vertical movement, akin to the description attendant  FIGS. 9 through 12 . 
     The round and square apertures  220 ,  222  can have some degree of adjustment after placement of the fastener  205 . The round  220  can be sized large relative to the diameter of the shaft of fastener  205 , thus enabling movement in a direction tangential to the round with minimal movement in the radial direction. Likewise, the alternative position  234  of the fastener  205  within the square  222  of  FIG. 16B  enables the z-bar to be adjusted laterally in both directions after placement of the fastener  205 . 
     The apertures that have corners (i.e. the square  222 , the triangle  224  and the diamond  226 ) can be utilized to provide a positive registration of the z-bar  180  with respect to the fastener  205  when the z-bar  180  is in a final position. For example, consider adjacent edges  236  and  238  of the diamond  226  ( FIG. 16D ). The fastener  205  may be positioned so that both of the adjacent edges  236  and  238  are in contact with the shaft of the fastener  205  when the z-bar  180  is in the desired alignment. 
     Referring to  FIGS. 17 through 20 , a z-bar  240  with a hanger plate  242  is depicted in an embodiment of the invention. The hanger plate  242  may be operatively coupled to an inward facing surface  244  of the web  245  of the z-bar  240  via a single flange  246  ( FIGS. 17 and 18 ) or with a pair of flanges  248  ( FIGS. 19 and 20 ). The hanger plate  242  may cooperate with a fastener  250  having a shaft portion  252  and a head portion  254  for suspension of the z-bar  240  from a structural member such as a door jamb (removed for clarity). 
     A variety of configurations may be implemented with the hanger plate  242  for securing the z-bar  240  during installation. For example, a v-notch  256  having inclined surfaces  258  and  260  can be formed on the hanger plate  242  so that the inclined surfaces  258 ,  260  register on the shaft  252  of the fastener  250  ( FIG. 18 ). The head  254  of the fastener  250  prevents the z-bar  240  from sliding off the shaft  252  during installation of the z-bar  240 . Other embodiments may include a closed slot  262  having a large diameter opening  264  and a smaller diameter opening  266 , similar to the through slots  186 ,  190  ( FIG. 19 ), an open-ended slot  268  with a divergent opening  270  and a narrow slot portion  272  ( FIG. 20 ), or any other through aperture (e.g.  FIGS. 16A through 16D ) formed on the hanger plate  242  to cooperate with the fastener  250 . The hanger plate  242  may include projections  274 , such as a pair of barbs ( FIGS. 18 and 19 ) or a ridge structure ( FIG. 19 ), that extend away from the interior side  244  of the z-bar  240 . 
     The hanger plate  242  may be mounted to the z-bar  240  in a variety of ways, such as by tack welds  276  ( FIG. 18 ), rivets  278  ( FIG. 19 ), threaded fastener  280  ( FIG. 20 ), gluing (not depicted) or by other fastening techniques available to the artisan. The hanger plate  242  may also be integrally formed with the z-bar  240 . 
     Functionally, the hanger plate  242  enables the z-bar to be mounted in ways similar to the through-holes or apertures without need to form a through-hole that passes through the web  245 , and may thus provide better isolation of inclement elements such as water, hot/cold air and humidity. The absence of a through hole and attendant fastener head on the externally facing surface of the z-bar can also provide aesthetic advantages. 
     The projections  274  provide a mechanism for marking the structural member (e.g. a door jamb) onto which the z-bar  240  is to be mounted for proper placement of the fastener  250 . The installer can align the z-bar  240  in a desired orientation on the structural member, then exert a force against the z-bar  240  such that the projections  274  leave an indentation on the structural member. Using the indentations as a guide, the fastener  250  can be located with sufficient accuracy for temporary mounting of the z-bar  240 . 
     In one embodiment, a method of mounting the z-bar  240  may be as follows:
         position z-bar  240  at desired location against a door jamb   press the z-bar  240  against the door jamb so structures leave indentation marks   remove z-bar  240  from the door jamb   identify the location on the door jamb where the fastener  250  will be installed (e.g. on a line between indentations, or according to some other characteristic of the indentation pattern)   center punch the location on the door jamb where the fastener  250  will be installed, leaving a center punch mark   place a gap gauge immediately adjacent the center punch mark   mount fastener so that the head portion  254  of the fastener  250  comes into light or touching contact with the gap gauge to set proper gap dimension between head portion  250  and the jamb   remove the gap gauge from between the head portion  254  and the jamb   mount z-bar  240  to fastener using cooperating structure of the hanger       

     The action that the installer undertakes to mount the z-bar  240  to the fastener  250  depends on the configuration of the hanger plate  242 . For example, with the v-notch  256 , the z-bar is lifted over the head portion  254  of the fastener  250  and hung on the shaft  252 . With the closed slot  262 , the installer aligns large diameter opening  264  over the fastener  250 , pushes the z-bar  240  over the head portion  254  of the fastener  250  until it engages the jamb, and slides the z-bar  240  so that the shaft portion  252  is located in the smaller diameter opening  266 . With the open-ended slot  268 , the z-bar  240  is slid over the fastener  250 , allowing the divergent opening  270  to guide the z-bar  240  until the z-bar  240  is positioned with the fastener  250  located in the narrow slot portion  272 . 
     References to relative terms such as upper and lower, front and back, left and right, or the like, are intended for convenience of description and are not contemplated to limit the present invention, or its components, to any specific orientation. All dimensions depicted in the figures may vary with a potential design and the intended use of a specific embodiment of this invention without departing from the scope thereof. 
     Each of the additional figures and methods disclosed herein may be used separately, or in conjunction with other features and methods, to provide improved containers and methods for making and using the same. Therefore, combinations of features and methods disclosed herein may not be necessary to practice the invention in its broadest sense and are instead disclosed merely to particularly describe representative and preferred embodiments of the instant invention. 
     Because various modifications, substitutions, and changes of this invention may be made by one of skill in the art without departing from the spirit thereof, the invention is not limited to the embodiments illustrated and described herein. Rather, the scope of the invention is to be determined by the appended claims and their equivalents. 
     For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked with respect to a given claim unless the specific terms “means for” or “step for” are recited in that claim.