Patent Publication Number: US-2021164286-A1

Title: Adjustable door frame mounting system and method

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. Provisional Patent Application No. 62/942,985 filed on Dec. 3, 2019, entitled “ADJUSTABLE DOOR FRAME MOUNTING SYSTEM AND METHOD,” the content of which is incorporated by reference herein in its entirety. 
    
    
     FIELD OF TECHNOLOGY 
     The present disclosure generally relates to a door frame mounting system and method, and more particularly relates to a pocket door frame kit designed to accommodate doors in different heights. 
     BACKGROUND 
     A pocket door is a type of door that opens by sliding along a track into a pocket enclosed within a wall. The door may likewise be closed by sliding it out of the wall pocket and across a doorway opening. When in an open position, the pocket door is hidden within the wall pocket resulting in a cleaner visual aesthetic and a more efficient use of available space than conventional swing doors. 
     Commercially available pocket door systems are offered either as kits with all the components included for installation or as pre-assembled units for doors of standard heights (e.g., 6 feet, 8 inches or 7 feet in length). Non-standard pocket doors use special tracks, hardware, and components of various dimensions which are required to be custom-built. 
     Accordingly, there is a need for providing an adjustable pocket door frame mounting system and method to accommodate doors of different heights. In particular, it is desirable to facilitate installations of pocket doors of different heights via commercially available pocket door frame kits in order to reduce the costs, delays, and inconveniences that are associated with custom-building relevant components. 
     SUMMARY 
     Among other features, the present disclosure provides a system, comprising: a plurality of first vertical support structures of a door frame construction, each first vertical support structure having a first length; a plurality of second vertical support structures, each second vertical support structure having a second length; and means for connecting at least one first vertical support structure and at least one second vertical support structure to achieve a desired door height. 
     In one aspect, the first length corresponds to an industry standard length of a door frame member. One or more second vertical support structures are configured to incrementally increase at least one first vertical support structure to the desired door height, wherein the second length is shorter than the first length and ranges from 6″ to 36″. Each of the first and second vertical support structures comprises a channel member configured to receive a wooden core. In one embodiment, the channel member has a substantially C-shaped or U-shaped cross-section and is made of heavy-gauge galvanized cold rolled steel or stainless steel. 
     In another aspect, the first and second vertical support structures are connected with each other at a selected distal end via the means. The selected distal end of each of the first and second vertical support structures comprises a first plurality of mounting holes for receiving a plurality of fasteners and attaching with the means. The means for connecting the first and second vertical support structures comprises a second plurality of mounting holes configured to align with the first plurality of mounting holes for receiving the plurality of fasteners. 
     The present disclosure also provides a kit for installing a pocket door system in a doorway. The kit comprises a frame header and track assembly installed horizontally at an uppermost end of a rough opening in a wall; and a plurality of vertical support structures fixed to the frame header and track assembly on one end to define a pocket opening in the wall for receiving a sliding door. Each vertical support structure includes at least one first vertical member having a first length, at least one second vertical member having a second length, and a component configured to connect the at least one first and second vertical members to a desired door height. 
     In one aspect, the first length corresponds to an industry standard length of a door frame member. The at least one second vertical member incrementally increases the at least one first vertical member to the desired door height, wherein the second length is shorter than the first length and ranges from 6″ to 36″. Each of the at least one first and second vertical members comprises a channel member configured to receive a wooden core. In one embodiment, the channel member has a substantially C-shaped or U-shaped cross-section and is made of heavy-gauge galvanized cold rolled steel or stainless steel. 
     In another aspect, the at least one first and second vertical members are connected with each other at a selected distal end via the component. The selected distal end of each of the at least one first and second vertical members comprises a first plurality of mounting holes for receiving a plurality of fasteners and attaching with the component. In one embodiment, the component has a substantially C-shaped or U-shaped cross-section and is made of heavy-gauge galvanized cold rolled steel or stainless steel. The component for connecting the at least one first and second vertical members comprises a second plurality of mounting holes configured to align with the first plurality of mounting holes for receiving the plurality of fasteners. 
     The present disclosure also provides a method for installing a pocket door system in a doorway. The method comprises installing a frame header and track assembly horizontally at an uppermost end of a rough opening in a wall; and fixing a plurality of vertical support structures to the frame header and track assembly, the plurality of vertical support structures defining a pocket opening in the wall for receiving a sliding door. Each vertical support structure includes at least one first vertical member having a first length, at least one second vertical member having a second length, and a component configured to connect the at least one first and second vertical members to a desired door height. 
     In one aspect, the first length corresponds to an industry standard length of a door frame member. The method further comprises incrementally extending the at least one first vertical member to the desired door height using the at least one second vertical member, wherein the second length is shorter than the first length and ranges from 6″ to 36″. Each of the at least one first and second vertical member comprises a channel member configured to receive a wooden core. In one embodiment, the channel member has a substantially C-shaped or U-shaped cross-section and is made of heavy-gauge galvanized cold rolled steel or stainless steel. 
     The method further comprises connecting the at least one first and second vertical members with each other at a selected distal end via the component, providing a first plurality of mounting holes on the selected distal end of each of the at least one first and second vertical members, and receiving a plurality of fasteners and attaching with the component via the first plurality of mounting holes. In one embodiment, the component has a substantially C-shaped or U-shaped cross-section and is made of heavy-gauge galvanized cold rolled steel or stainless steel. 
     The method further comprises providing a second plurality of mounting holes on the component for connecting the first and second vertical members, aligning with the first and second plurality of mounting holes for receiving the plurality of fasteners, extending each vertical support structure to the desired door height using two or more second vertical members, and attaching the at least one second vertical member to a top edge or a bottom edge of the at least one first vertical member. 
     The above simplified summary of example aspects serves to provide a basic understanding of the present disclosure. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements of all aspects nor delineate the scope of any or all aspects of the present disclosure. Its sole purpose is to present one or more aspects in a simplified form as a prelude to the more detailed description of the disclosure that follows. To the accomplishment of the foregoing, the one or more aspects of the present disclosure include the features described and exemplary pointed out in the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more example aspects of the present disclosure and, together with the detailed description, serve to explain their principles and implementations. 
         FIG. 1  illustrates a pocket door frame mounting system, according to an exemplary aspect of the present disclosure; 
         FIG. 2  illustrates a first jamb member having a first length, according to an exemplary aspect of the present disclosure; 
         FIG. 3  illustrates a second jamb member having a second length, according to an exemplary aspect of the present disclosure; 
         FIGS. 4( a ) and 4( b )  illustrate various views of the first and second jamb members connected by a component to form an integral vertical support structure of the pocket door frame mounting system of  FIG. 1 , according to an exemplary aspect of the present disclosure; and 
         FIG. 5  illustrates a component for connecting the first and second jamb members, according to an exemplary aspect of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various aspects of the present disclosure will be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to promote a thorough understanding of one or more aspects of the invention. It may be evident in some or all instances, however, that any aspects described below can be practiced without adopting the specific design details described below. 
     Referring to  FIG. 1 , a pocket door frame mounting system  10  is illustrated, according to aspects of the present disclosure. System  10  may be installed within a rough opening in a load-bearing or non-bearing wall, prior to the installation of drywalls or other suitable types of wall surface finish. System  10  may include a frame header and track assembly  12  installed horizontally at an uppermost end of the rough opening and a plurality of vertical support structures  14   a ,  14   b ,  14   c , and  14   d  fastened to the assembly  12  to form a rigid pocket frame structure. System  10  may be configured to support and house a sliding door or panel member  16  for rectilinear movement across a door opening and into and out of a recessed or hidden pocket spacing between the vertical support structures  14   a - 14   d  positioned between two opposing walls of a structural wall or partition. The frame header and track assembly  12  may provide a pair of opposing track portions  18  extending downwardly from a central plate portion  20 . Each track portion  18  may generally have a C-shaped cross section in configuration and is spaced from each other to receive trolley assemblies  22  which may be secured to an upper edge of the sliding door  16  via any suitable means. In one embodiment, the maximum weight load of the frame header and track assembly  12  of system  10  may be up to 250 lb. Trolley assemblies  22  may include two or more rollers  24  that are spaced apart from each other in order to move in each respective track portions  18 , such that the sliding door  16 , which is suspended from the trolley assemblies  22  and above the floor, may freely move in the door opening and into and out of the wall pocket between a fully open position and a fully closed position. The spacing between two opposing pair of vertical support structures  14   a ,  14   b  and  14   c ,  14   d  may be configured to accommodate the sliding door  16  of different thicknesses ranging from, e.g., 1⅜″ to 1¾″. 
     According to aspects of the present disclosure, the length of each vertical support structure  14   a - 14   d  may be configured to be adjustable or extendable to provide a desired pocket door height. In one embodiment, as shown in  FIGS. 1, 2, 3, 4 ( a ) and  4 ( b ), each vertical support structure  14   a - 14   d  may comprise two or more jamb members  26 ,  28  that may be in different lengths and configured to join or connect with each other securely via a connector component  42 . 
     Referring to  FIG. 2 , a first jamb member  26  may have a first length (e.g., an industry standard wall stud length of 82-88″). Jamb member  26  may include a channel member  30  configured to receive a wooden core  32 . The channel member  30  may be made of heavy-gauge galvanized cold rolled steel or stainless steel in order to resist rust due to rain or ambient humidity in the environment surrounding system  10  and maintain a rigid pocket structure of system  10 . In one embodiment, channel member  30  may be generally C-shaped or U-shaped having a base panel  30   a  and two opposing and substantially parallel legs or side walls  30   b  for placing over and wrapping around the wooden core  32 , which may have a rectangular cross section, on three continuously adjacent surfaces. The wooden core  32  may extend substantially the full width and length of a corresponding channel member  30  and provide one surface for receiving any suitable fastening means thereon. Connecting means such as multiple mounting holes  34  may be provided on, e.g., a selected distal end  26   a  of the channel member  30  and the wooden core  32 , for receiving corresponding fasteners, such that jamb member  26  may securely connect with other components of system  10  to achieve a desired pocket door height, as will be described fully below. In one embodiment, a portion of the mounting holes  34  may be positioned along each side wall  30   b  and along a centerline of the base panel  30   a  of the channel member  30 , respectively. 
     Referring to  FIG. 3 , according to aspects of the present disclosure, a second door jamb member  28  may have a second length (e.g., 6″-36″) or a length shorter than the first jamb member  26 . One of the functions of jamb member  28  may include incrementally extending the length of the first jamb member  26  to a desired door height. Jamb members  26  and  28  may be structurally similar to each other (e.g., having substantially the same profile and construct), thereby providing the necessary mechanical strength and durability when joined together. Jamb member  28  may similarly include a channel member  36  having a substantially C-shaped or U-shaped cross-section with a base panel  36   a  and two opposing and substantially parallel legs or side walls  36   b  for placing over and wrapping around a wooden core  38 , which may have a rectangular cross section, on three continuously adjacent surfaces. The channel member  36  may be made of heavy-gauge galvanized cold rolled steel or stainless steel in order to resist rust due to rain or ambient humidity in the environment surrounding system  10  and maintain a rigid pocket structure of system  10 . The wooden core  38  may extend substantially the full width and length of a corresponding channel member  36  and provide one surface for receiving any suitable fastening means thereon. Connecting means such as a number of mounting holes  40  may be provided on, e.g., a selected distal end  28   a  of the channel member  36  and the wooden core  38 , for receiving corresponding fasteners, such that jamb member  28  may securely connect with other components of system  10  to achieve a desired pocket door height, as will be described fully below. In one embodiment, a portion of the mounting holes  40  may be positioned along each side wall  36   b  and along a centerline of the base panel  36   a  of the channel member  36 , respectively. 
       FIGS. 1, 4 ( a ) and  4 ( b ) show two jamb members  26  and  28  securely and removably joined together via a connector component  42  to form one or more vertical support structures (e.g.,  14   a - 14   d  shown in  FIG. 1 ) of system  10 . According to aspects of the present disclosure, the length of each jamb member  26 ,  28  may be independently adjusted (e.g., cut or saw to a desired length on one end), and a combined length of both jamb members when joined together may accommodate a pocket door height ranging from, e.g., 6 feet, 8 inches to 9 feet. For example, where the height of a pocket door exceeds a standard-length jamb member (e.g., the length of jamb member  26 ) provided in a commercially available pocket door frame kit, one or more jamb extension members  28  may be adjusted in length accordingly and securely fastened to the standard-length jamb member via the connector component  42  in an end-to-end abutment in order to achieve a desired door height. As described above in connection with  FIGS. 2 and 3 , distal ends  26   a  and  28   a  of jamb members  26  and  28  may be configured to include suitable connecting means (e.g., a number of mounting holes  34  and  40 ) for attaching with the connector component  42 . It should be appreciated that any other suitable connecting means such as adhesive, frictional tabs, insert-molding techniques may be use for attaching jamb members  26 ,  28  and the connector component  42  together. 
     As shown in  FIGS. 1, 4 ( a ),  4 ( b ), and  5 , the connector component  42  may be generally U-shaped having a base panel  44  and two opposing and substantially parallel legs or side walls  46 , similar to the cross section of the channel members  30  and  36 . The connector component  42  may be made of heavy-gauge galvanized cold rolled steel or stainless steel in order to resist rust due to rain or ambient humidity in the environment surrounding system  10 . The width of the base panel  44  may be slightly greater than that the channel members  30  and  36 , such that when engaged together, the connector component  42  may tightly wrap around the jamb members  26  and  28  to ensure sufficient mechanical strength and stability at the joint. A number of mounting holes  48  and  50  may be provided on the base panel  44  and each leg  46 , respectively. In one embodiment, in order to attach and hold two proximately abutting jamb members  26  and  28  in place, the connector component  42  may be positioned to have a tight engagement with the outer surface of channel members  30  and  36 . Further, mounting holes  48  and  50  along the centerline of base panel  44  and on each leg  46  may be correspondingly aligned with the mounting holes  34  and  40  of each jamb member  26  and  28  to allow the installation of a number of fasteners therethrough in order to prevent any lateral movement between jamb members  26  and  28  at the joint. 
     Optionally, an additional connector component  42  may be used to wrap around the jamb members  26 ,  28  at a selected position and have a tight engagement with the outer surface of wooden cores  32  and  38  and the side walls  30   b  and  36   b  of the channel members  30  and  36 , thereby providing increased mechanical strength and durability. 
     As shown in  FIG. 1 , jamb member  28  may be attached to the top of jamb member  26 , thereby providing an extension of length from the top edge of jamb member  26  to the header and track assembly  12 . In a different embodiment, jamb member  28  may be attached to the bottom of jamb member  26 , thereby providing an extension of length from the bottom edge of jamb member  26  to the floor. Further, it should be appreciated that any number of jamb members  26  and  28  may be connected together via one or more connector components  42  to achieve a desired door height. 
     In yet another embodiment, the door frame mounting system  10  of the present disclosure may be used in curved walled enclosures such as airplanes, submarines, space shuttles, railroad cars, buses and the like. 
     The above description of the disclosure is provided to enable a person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the common principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Further, the above description in connection with the drawings describes examples and does not represent the only examples that may be implemented or that are within the scope of the claims. 
     Furthermore, although elements of the described aspects and/or embodiments may be described or claimed in the singular, the plural is contemplated unless limitation to the singular is explicitly stated. Additionally, all or a portion of any aspect and/or embodiment may be utilized with all or a portion of any other aspect and/or embodiment, unless stated otherwise. Thus, the disclosure is not to be limited to the examples and designs described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.