Patent Publication Number: US-7584588-B2

Title: Door frame system having fixed bench, pressure bench, and compression rail

Description:
RELATED APPLICATION 
   This application is a corresponding non-provisional application of U.S. Provisional Patent Application Ser. No. 60/798,076 for “Door Frame System” filed on May 5, 2006. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a door frame system for a glass door of a building, and more particularly, to a door frame system, which includes a fixed bench not moving when assembled, a horizontally movable pressure bench, a compression rail pushing the pressure bench in a horizontal direction only, and a frame to which the fixed bench, the pressure bench, and the compression rail are assembled, so that the assembled frame is combined with a glass pane. 
   2. Background Art 
   U.S. Pat. No. 6,434,905 issued on Aug. 20, 2002 discloses a door rail system. Referring to  FIG. 15 , the door rail system of the prior art includes: a housing  102  having inclined slide surfaces  122  narrowing downwardly; a pair of clamp members  104   a  and  104   b,  each having an inclined friction surface  120  in parallel with the inclined slide surface  122 ; a nut strip  108  coupled with a bolt  106  pulling the clamp members  104   a  and  104   b  in one direction so as to simultaneously close the clamp members  104   a  and  104   b,  so that the clamp members can be combined with the glass pane  101 . 
   In more detail, the housing  102  includes the inclined slide surfaces  122  formed at both sides of the upper space thereof in a downward direction and double-layer type bridges  116  and  118 . Each clamp member includes the inclined friction surface  120  sliding on the inclined slide surface  122  and a recess  104   a ′ or  104   b ′ formed at the lower portion thereof. An elongated nut strip  108  which has at least two female screw holes  108   a  is located in the recess  104   a  and  104   b,  and a bolt  106  passes through holes  116   a  and  118   a  perforating the bridges  116  and  118  of the housing  102  and inserted into the female screw hole of the nut strip  108 . 
   A process for manufacturing the door rail system of the prior art is described below. First, the clamp members  104   a  and  104   b  are coupled with each other in such a way that the inclined friction surfaces  120  are respectively in contact with the inclined slide surfaces  122  of the housing  102 , and the recesses  104   a ′ and  104   b ′ face with each other, and then, the elongated nut strip  108  is pushed into the recesses  104   a ′ and  104   b′.    
   Next, the bolt  106  is inserted into the through holes  116   a  and  118   a,  and then, rotated in such a way as to be fit into the female screw hole  108   a  of the nut strip. 
   The housing  102  to which the above components are assembled is combined to the upper surface and the lower surface of the glass pane  101  put on a table. 
   The combining method is as follows. Both ends of the clamp members  104   a  and  104   b  are adjusted to be fit with both ends of the housing  102 , and then, the bolt  106  is loosened or tightened in such a way that the glass pane  101  is fit between the clamp members  104   a  and  104   b.  After an interval between the clamp members  104   a  and  104   b  is adjusted, the clamp members  104   a  and  104   b  are fit to the ends of the glass pane  101  in a state where two workers grasp both ends of the glass pane  101 , so that the clamp members  104   a  and  104   b  do not separated out from the inside of the housing  102 . After that, one worker grasps the housing  102  and the other tightens the bolt  106  so as to combine the housing  102  with the glass pane  101 . 
   As described above, in the prior art, the glass pane is assembled with the housing according to such difficult method, however, when the bolt  106  is tightened to completely assemble the housing  102  to the glass pane  101 , the clamp members  104   a  and  104   b  are unsteadily tightened and do not keep a straight line condition with the glass pane  101  while the bolt  106  is tightened. 
   Furthermore, the clamp members  104   a  and  104   b  are pulled outwardly from the ends of the glass pane  101  while the bolt  106  is tightened. So, finally, the door becomes longer than a set length of a standard door and is not up to the standard, so that workers must repeat attaching and detaching action of the door till the door is fit to a doorframe of a building when the door is installed to the building. 
   SUMMARY OF THE INVENTION 
   Accordingly, the present invention has been made to solve the above problems occurring in the prior arts, and it is an object of the present invention to provide a door frame system, which includes: a bench guide formed at a side of the upper part of a frame; a fixed bench detachably mounted on the bench guide and not moving when assembled to the frame; a pressure bench mounted at the front side of the fixed bench for supporting the base side of the fixed bench and compressing a glass pane by moving only in a horizontal direction; a compression rail mounted between the pressure bench and the frame for horizontally moving the pressure bench during ascending upwardly; screw holes formed on a bridge of the frame and opened in a direction facing each other; thick pressure sustaining portions formed at sides of the screw holes, wherein the pressure sustaining portions is not transformed under a heavy pressure; a tightening bolt inserted into a bolt hole perforating the center of the pressure sustaining portions, wherein the tightening bolt pushes the compression rail upwardly; and a brush assembly combined at the bottom of a vertical wall surface of the frame, thereby prevents dust or pollutant air from entering, and allows even a unskilled person to assemble a door easily, rapidly and correctly assemble without departing from the standard. 
   To accomplish the above objects, according to the present invention, as shown in  FIG. 3 , there is provided a door frame system including a fixed bench combined at one side of the upper part of a frame for determining a fixed position of a glass pane, a pressure bench for horizontally pushing the glass pane so that the glass pane and the fixed bench are in close contact with each other, a compression rail for horizontally pushing the pressure bench, and a frame to which the fixed bench, the pressure bench and the compression rail are assembled, wherein the assembled frame being combined with the glass pane. 
   The frame includes an upper space portion, a middle space portion, and a lower space portion. Both sides of the upper space portion get thicker downwardly and respectively have inclined portions for keeping a uniform angle. 
   As shown in  FIG. 4 , a flat inclined portion having no slide structure is formed at the right in the drawing, and bench guides are formed at upper and lower portions of the front surface facing the inclined surface portion. The bench guide has a guide groove. 
   A bridge is formed at the middle space portion of the frame in a double layer form. 
   The upper bridge includes a support jaw having a support recess  203   a,  screw holes formed on the upper and lower portions of the center thereof at an interval of 10 mm, pressure sustaining portions formed at sides of the screw holes and reinforced thick to endure a heavy load, and bolt holes formed vertically. 
   The lower space portion of the frame includes balance member guide grooves and brush guide grooves respectively formed at the central portions and lower end portions of both vertical wall surfaces thereof. 
   The fixed bench, the pressure bench, and the compression rail are assembled and combined to the frame. First, as shown in  FIGS. 9   a  and  9   b , the fixed bench includes a vertical wall closely contacting with a wide end side of the glass pane, a horizontal wall formed on a base side at a right angle to the vertical wall and closely contacting with a cut end portion of the glass pane, a rail formed at the center of the rear side thereof and fit into the guide groove of the frame, a stable protrusion and a seating protrusion formed at both ends of the base side, which are seated on the support jaw of the frame and a low jaw of the pressure bench. 
   As shown in  FIGS. 11   a  and  11   b , the pressure bench facing the fixed bench and combined to the frame includes a vertical wall closely contacting with a wide end side of the glass pane, a horizontal wall formed on a base side at a right angle to the vertical wall and closely contacting with a cut end portion of the glass pane, an upwardly protruding low jaw horizontally formed below the horizontal wall seating the base side and the seating protrusion of the fixed bench, a downwardly protruding friction portion formed at both sides of the base side thereof and seated on the bridge, a pressure portion getting thicker toward the center of the rear side thereof, and a holding portion, a stepped-form restriction portion and an inclined pressure portion formed below the pressure portion. 
   Furthermore, as shown in  FIGS. 8   a  and  8   b,  the compression rail is in the form of a triangle when it is seen based on both sides of the base side and an apex in section. 
   In the drawings, the compression rail includes first upper and lower friction surfaces formed at upper and lower portions of the rear side, second upper and lower friction surfaces formed at the opposed side and closely acting to the pressure portion of the pressure bench, a holding portion and a recess to which the holding portion and restriction portion of the pressure bench are entered and seated, the holding portion and the recess being formed between the second upper and lower friction surfaces, and a rising restriction portion. 
   In addition, as shown in  FIG. 3 , a tightening bolt for pushing the compression rail upwardly is fit into the bolt holes vertically perforating the center of the pressure sustaining portion of the bridge. Additionally, as shown in  FIG. 13 , a brush assembly is combined to the lower end of the frame, and the brush assembly includes right-angled upper and lower wings directing vertically, an elastic slot formed between the wings, a brush guide formed at a right angle to the wings and having a brush guide groove, and a brush fit to the brush guide groove. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the invention in conjunction with the accompanying drawings, in which: 
       FIG. 1  is a perspective view showing an assembled state of the present invention; 
       FIG. 2  is a front view for explaining action of the present invention; 
       FIG. 3  is a sectional view showing an assembled state of a frame system according to the present invention; 
       FIG. 4  is a sectional view for explaining a structure of a frame according to the present invention; 
       FIG. 5   a  is a perspective view showing a door finished according to the present invention; 
       FIG. 5   b  is an enlarged view taken along the circle of  FIG. 5   a;    
       FIG. 6  is a front view showing a state where the door finished according to the present invention is installed in a building; 
       FIG. 7  is a partially enlarged sectional view of essential parts according to the present invention; 
       FIG. 8   a  is a perspective view of a compression rail according to the present invention; 
       FIG. 8   b  is a sectional view of the compression rail of  FIG. 8   a;    
       FIG. 9   a  is a perspective view of a fixed bench according to the present invention; 
       FIG. 9   b  is a sectional view of the fixed bench of  FIG. 9   a;    
       FIG. 10  is an exemplary view showing a working state of the compression rail; 
       FIG. 11   a  is a perspective view of a pressure bench according to the present invention; 
       FIG. 11   b  is a sectional view of the pressure bench of  FIG. 11   a;    
       FIG. 12  is a perspective view of a brush assembly according to the present invention; 
       FIG. 13  is a sectional view of a brush rail in a state where a brush is removed from  FIG. 12 ; 
       FIG. 14   a  is a perspective view of an end cap according to the present invention; 
       FIG. 14   b  is a sectional view of the end cap of  FIG. 14   a;    
       FIG. 15  is a sectional view of a prior art door rail system; 
       FIG. 16  is a sectional view of a clamp member of  FIG. 15 ; and 
       FIG. 17  is a sectional view of a nut strip of  FIG. 15 . 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The U.S. Provisional Patent Application Ser. No. 60/798,076 by the applicant is incorporated by reference into this disclosure as if fully set forth herein. 
   Reference will be now made in detail to the preferred embodiment of the present invention with reference to the attached drawings. 
     FIG. 1  is a perspective view showing an assembled state of the present invention,  FIG. 2  is a front view for explaining action of the present invention,  FIG. 3  is a sectional view showing an assembled state of a frame system according to the present invention,  FIG. 4  is a sectional view for explaining a structure of a frame according to the present invention,  FIG. 5   a  is a perspective view showing a door finished according to the present invention,  FIG. 5   b  is an enlarged view taken along the circle of  FIG. 5   a,    FIG. 6  is a front view showing a state where the door finished according to the present invention is installed in a building,  FIG. 7  is a partially enlarged sectional view of essential parts according to the present invention,  FIG. 8   a  is a perspective view of a compression rail according to the present invention,  FIG. 8   b  is a sectional view of the compression rail of  FIG. 8   a,    FIG. 9   a  is a perspective view of a fixed bench according to the present invention,  FIG. 9   b  is a sectional view of the fixed bench of  FIG. 9   a,    FIG. 10  is an exemplary view showing a working state of the compression rail,  FIG. 11   a  is a perspective view of a pressure bench according to the present invention,  FIG. 11   b  is a sectional view of the pressure bench of  FIG. 11   a,    FIG. 12  is a perspective view of a brush assembly according to the present invention,  FIG. 13  is a sectional view of a brush rail in a state where a brush is removed from  FIG. 12 ,  FIG. 14   a  is a perspective view of an end cap according to the present invention,  FIG. 14   b  is a sectional view of the end cap of  FIG. 14   a,    FIG. 15  is a sectional view of a prior art door rail system,  FIG. 16  is a sectional view of a clamp member of  FIG. 15 , and  FIG. 17  is a sectional view of a nut strip of  FIG. 15 . 
   Essential parts of the present invention are described below. 
   A door frame system according to the present invention includes: a frame  200  serving as a body to which all essential parts are combined; a fixed bench  300  fit into a bench guide groove  201  and closely contacting with a glass pane G; a pressure bench  400  combined to the front surface of the fixed bench  300 , sliding only in a horizontal direction, and strongly compressing the glass pane G; a compression rail  500  pushing the pressure bench in order to move it in the horizontal direction; a tightening bolt B/T lifting the compression rail upwardly; and a brush assembly  600  for preventing contaminant and serving as a weather strip. 
   As shown in  FIG. 4 , the frame  200  serving as the body includes an upper space portion A, a middle space portion B, and a lower space portion C. 
   The upper space portion A of the frame  200  is in a trapezoidal form which is narrowed upwardly, and includes: inclined portions  200   a  and  200   b  formed on the wall surface thereof and getting gradually thicker downwardly; a flat guide surface  200   b ′ formed on the right inclined portion  200   b  with no structure; bench guides  202   a  and  202   b  formed at the center of the other inclined portion  200   a  facing the inclined portion  200   b  and having the guide groove  201 . The fixed bench  300  is combined with the frame  200 . A structure of the fixed bench  300  will be described in more detail. 
   The middle space portion  200   b  of the frame  200  includes: a support jaw  203  having a support recess  203   a  formed at one side of the upper surface thereof; screw holes  205   a  and  205   b  facing each other, pressure sustaining portions  206   a  and  206   b  formed at sides of the screw holes  205   a  and  205   b  and reinforced thick; and bolt holes  207   a  and  207   b  formed vertically, so that the tightening bolt B/T is fastened to the frame in such a way as to direct upwardly from the bottom. 
   Furthermore, the lower space portion  200   c  of the frame  200  includes: vertical wall surfaces  208   a  and  208   b  formed at both sides thereof; balance member guide grooves  209   a  and  209   b  formed at the central portions of the vertical wall surfaces  208   a  and  208   b;  and brush grooves  210   a  and  210   b  formed on the lower portions of the vertical wall surfaces  208   a  and  208   b  so that the brush assembly  600  is combined to the frame  200  through the brush grooves  210   a  and  210   b.  Moreover, a balance member  800  and a hinge link  900  are also combined to the frame  200  through the balance member guide grooves  209   a  and  209   b.    
   Meanwhile, as shown in  FIGS. 9   a  and  9   b , the fixed bench  300  fit to the bench guide groove  201  of the frame  200  is in a right-angled form, and includes: a high vertical wall  301  formed on one side thereof; a narrow horizontal wall  302  formed on the base side thereof; a rail  304  formed on a rear side  303  thereof in a longitudinal direction; and a stable protrusion  306  and a seating protrusion  307  formed at both sides of the base side  305 . Such fixed bench  300  is fit to the guide groove  201  of the frame  200 . 
   To combine the fixed bench  300  to the frame  200 , in a state where one end portion of the rail  304  is located at the front end portion of the bench guide groove  201  of the frame and the stable protrusion  306  is located at the support recess  203   a,  the worker applies some power to the fixed bench  300  so that the fixed bench  300  is stably pushed in the longitudinal direction so as to be combined to the frame  200 . 
   Then, the rail  304  of the fixed bench  300  is fit to the bench guide groove  201  of the frame  200 , and at the same time, the rear side  303  is in close contact with the front surface of the bench guides  202   a  and  202   b,  and the stable protrusion  306  formed on the base side  305  of the fixed bench  300  is seated on the support recess  203   a  formed on the support jaw  203   b  of the frame  200 , whereby the fixed bench  300  can be combined integrally with the frame  200 . 
   Moreover, the pressure bench  400  is combined to the front side of the fixed bench  300  in such a way as to face with the fixed bench  300 , and at this time, a space Y for fitting the glass pane thereof is formed between the fixed bench  300  and the pressure bench  400 . As shown in  FIGS. 11   a  and  11   b , the pressure bench  400  is in a right-angled form, and includes: a high vertical wall  401  formed on the left side thereof in the drawings; a narrow horizontal wall  402 ; a low horizontal jaw  405  stepped downwardly from the horizontal wall  402  and having an upwardly protruding support portion  403 ; downwardly protruding friction portions  404  formed at both sides of the bottom surface of the low horizontal jaw  405 ; a pressure portion  407 a protruding from the center of a rear side  406  of the vertical wall  401 , the rear side  406  of the vertical wall  401  getting thicker toward the center thereof; a holding portion  408  formed below the pressure portion  407   a  and directing upwardly; and a stepped-form restriction portion  409  and an inclined pressure portion  407   b formed beneath the holding portion  408 . 
   Meanwhile, to combine the pressure bench  400  to the front side of the fixed bench  300 , as shown in  FIG. 3 , the support portion  403  and the low horizontal jaw  405  are directed downwardly and fit to the base side  305  of the fixed bench  300  in such a way that they support the base side  305 , and at the same time, the base side  305  and the seating protrusion  307  of the fixed bench  300  are pushed inwardly from one side end thereof in such a way that they are seated on the upper surface of the low horizontal jaw  405  and the support portion  403  of the pressure bench  400 . 
   Then, the base side  305  and the seating protrusion  307  of the fixed bench  300  are fit to the support portion  403  and the low horizontal jaw  405  of the pressure bench  400  in such a way that they are seated on the upper surfaces of the support portion  403  and the low jaw  405 . And, at the same time, the friction portion  404  of the pressure bench  400  is fit to the bridge  204   a  of the frame  200  in such a way that the friction portion  404  is seated on the upper surface of the bridge  204   a.    
   Continuously, the compression rail  500  is mounted between the guide surface  200   b ′ of the frame  200  and the rear side  406  of the pressure bench  400 . At this time, as shown in  FIGS. 8   a  and  8   b,  the compression rail  500  is in the form of a triangle when it is seen based on both sides of a base side  501  and an apex  502  in section, and includes: first upper and lower friction surfaces  504   a  and  504   b  formed partially at upper and lower portions of a rear side  503  on the right in the drawing in order to reduce a friction area; second upper and lower friction surfaces  508   a  and  508   b  formed on the left side; and a downwardly formed holding portion  505 , a recess  507 , and a stepped-form rising restriction portion  506  formed between the second upper and lower friction surfaces  508   a  and  508   b.  The compression rail  500  is mounted between the guide surface  200   b ′ of the frame  200  and the rear side  406  of the pressure bench  400 . 
   To combine the compression rail  500  to the frame  200 , one end portion of the recess  507  is coincided with the holding portion  408  of the pressure bench  400 , the second upper and lower friction surfaces  508   a  and  508   b  are coincided with the pressure portions  407   a  and  407   b  of the pressure bench  400 , and the first upper and lower friction surfaces  504   a  and  504   b  of the rear side  503  are coincided with the front end portion of the guide surface  200   b ′ of the frame  200 . After that, the compression rail  500  is pushed in a longitudinal direction slowly. 
   Then, the holding portion  408  and the restriction portion  409  of the pressure bench  400  are fit to the recess  507  and the restriction portion  506  of the compression rail  500 , and at the same time, the first and second upper and lower friction surfaces  504   a  and  504   b  and  508   a  and  508   b  are combined to the guide surface  200   b ′ of the frame  200  and the pressure portions  407   a  and  407   b  of the pressure bench  400  in a closely contacting state. 
   Meanwhile, as shown in  FIG. 13 , the brush assembly  600  combined to one of the two brush grooves  210   a  and  21 O b  formed at the lower end portions of the vertical wall surfaces  208   a  and  208   b  of the frame  200  includes: wings  603   a  and  603   b  formed vertically; an elastic slot formed at the center between the wings  603   a  and  603   b ; a brush guide  602  formed at right angle to the wings  603   a  and  603   b ; and a brush  600 A fit integrally to a brush guide groove  602   a  and having bristles which splay outwardly at the bottom ends thereof. 
   The assembled frame  200  is combined with the glass pane G prepared on a table or a work stand. 
   To combine the glass pane G with the frame  200 , the worker lifts up the frame  200  with his or her hand, fits it to an end portion of the glass pane G, and then, fastens them with the tightening bolt B/T, whereby the frame  200  is fixed to the glass pane G. 
   In other words, the worker lifts up the assembled frame  200 , locates the end portion of the glass pane G in the space Y of the frame  200  for fitting the glass pane G, and then, turns the tightening bolt B/T in a locking direction. 
   When the tightening bolt B/T is turned in the locking direction, the compression rail  500  minutely moves the pressure bench  400  in a horizontal direction along the guide surface  200   b′.    
   That is, five bolt holes  207   a  and  207   b  formed on the pressure sustaining portions  206   a  and  206   b  of the frame  200 , which has a length corresponding to a width of a door, are formed at intervals of about 5˜6 inches, and the tightening bolt B/T of 8 mm is fit into each bolt hole. 
   Each tightening bolt B/T is turned and locked while keeping its balance till it is inserted to a predetermined depth. An end portion of the tightening bolt B/T protrudes upwardly from the pressure sustaining portions  206   a  and  206   b,  and then, the locked tightening bolt B/T is idly rotated at the base side  501  of the compression rail  500  and pushes the compression rail  500  upwardly. 
   In addition, while the compression rail  500  is lifted upwardly by the tightening bolt B/T, the first upper and lower friction surfaces  504   a  and  504   b  of the rear side  503  are in close contact with the guide surface  200   b ′ of the frame  200 , and the second upper and lower friction surfaces  508   a  and  508   b  of the opposed side are in close contact with the pressure portions  407   a  and  407   b  respectively formed at upper and lower portions of the rear side  406  of the pressure bench  400 . So, the compression rail  500  slides upwardly in a state where it is in close contact with the pressure bench  400 during it slides along the inclination angle of the guide surface  200   b ′, so that the compression rail  500  can firmly combine the frame  200  with the glass pane G by pushing the pressure bench  400  to the left in the drawing. 
   After the above operation, the balance member  800  is fit into the balance member guide grooves  209   a  and  209   b  formed on the vertical wall surface  208 , and then, the hinge link  900  is combined to the balance member  800  with bolts. After that, end caps  700  are positioned at both ends of the frame  200  and fastened to the frame  200  with flat countersunk head screws  700   a.  By the above process, the door, which can be installed on a door frame of the building, is finished. 
   As described above, the present invention can be rapidly assembled within a short time period by only one worker since the fixed bench, the pressure bench, and the compression rail are firmly fastened in the upper space portion of the frame without separation. 
   Moreover, the present invention can be correctly assembled in a state where the frame and the glass pane keep a straight line condition without slant and provide an exact standard without transformation in length of the door, since the glass pane is fixed to the frame and fastened by the tightening bolts without vertical movement in a state where the fixed bench is fixed and only the pressure bench is horizontally movable. 
   Furthermore, the present invention can provide soundproof and mothproof effects and prevent incoming of dust or foreign matters to the inside of the building, since end portions of vertical wall surfaces of the frames installed at the top and bottom of the door are ventilated but combined with the brush assembly of thick fur to filter foreign matters. 
   While the present invention has been described with reference to the particular illustrative embodiments, it is not to be restricted by the embodiments but only by the appended claims. It is to be appreciated that those skilled in the art can change or modify the embodiments without departing from the scope and spirit of the present invention.