Patent Publication Number: US-2010115864-A1

Title: Adjustable Frame Assembly for Fire Rated Building Opening

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present invention claims the benefit of U.S. Provisional Patent Application Ser. No. 61/113,798 entitled “Adjustable Frame Assembly for Fire Rated Building Opening” filed Nov. 12, 2008. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention pertains to the construction field and, more particularly, to an adjustable door, window or the like frame assembly for use in building construction. Even more specifically, the invention is directed to fixedly mounting a versatile frame assembly in a framed building opening in a simple, adjustable manner while establishing a high fire rating. 
     2. Discussion of the Prior Art 
     In the construction industry, it is common to establish internal wall openings for doors, windows, closable pass-throughs and the like. As there actually exists a range in the size of the openings, specifically variations in at least both lateral and thickness dimensions, pre-manufactured frames that vary in size are available. To minimize the number of frame configurations which need to be produced, it is known to produce a frame, such as a door frame, which is adjustable in thickness. Such an adjustable frame assembly is particularly common in connection with metal door frames which can be used in residential construction but are more typically found in commercial building construction. For example, a typical adjustable metal door frame assembly will include a pair of hinge jamb components, a pair of striker jamb components and a pair of header components, with the pairs being joined through respective tongue and groove connections. More specifically, each of the grooved jamb and header components are fixed along one side of the doorway and then the other jamb and header components are slid into position from the other side of the doorway, with a tongue portion of each of the other jamb and header components being received in a respective groove of the fixed jamb and header components until flange or facer portions of the sliding components abut the wall. With this arrangement, the tongue and groove connections permit a single door frame assembly to be used with walls which vary in thickness. 
     Certainly, it is desired to mount the fixed frame components in a manner which will establish a rigid and sturdy assembly, particularly in the case of metal door frames given the fact that such metal door frames are typically used to support relatively heavy metal doors. In the past, numerous mounting configurations have been proposed in an attempt to achieve a sturdy and robust assembly, while attempting to provide for a relatively easy mounting sequence for the door assembly. Regardless of the availability of various mounting arrangements, there still exists a need for an enhanced mounting system for the fixed components of an adjustable metal frame assembly, particularly the fixed hinge jamb component of a metal door frame assembly. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an adjustable frame assembly and, more particularly, to a mounting arrangement for one or more of the fixed components of a multi-component adjustable frame assembly. In accordance with a preferred embodiment of the invention, the frame assembly is used to mount a door such that the overall door frame assembly includes hinge jamb, striker jamb and header components, with each of these components being formed from two separate members, i.e., a fixed member and a slidingly interconnected member, which enable the adjustable door frame assembly to be used with walls having varying thicknesses. However, the overall adjustable frame assembly of the invention can extend to other types of openings, such as internal windows, pass-through zones and the like. One particular aspect of the present invention is concerned with the manner in which the fixed members of a door frame assembly are mounted and, most importantly, the mounting of at least the fixed member of the hinge jamb component. 
     In accordance with the adjustable frame assembly of the invention, a rigid and sturdy frame construction is preferably established utilizing sets of brackets to secure one or more fixed frame components to one side of an opening, such as a doorway. In a first embodiment of the invention, each set includes two brackets. A first one of the brackets includes one portion which slips between a stud defining the opening and an adjacent wallboard and another portion which extends along the stud and is mechanically secured thereto. The second of the two brackets is fixed to or integrally formed with a respective fixed frame component. The two brackets are interconnected to indirectly fix the frame component to the wall. 
     Once all the fixed frame members are secured, such as in a corresponding manner to the fixed hinge jamb member described, the other frame members can be readily slid into place and preferably joined by a friction fit. In further accordance with the present invention, an optional spacer plate arrangement can be installed between the first and second brackets in order to accommodate varying opening widths for the overall frame assembly. Therefore, with this arrangement, the adjustable frame assembly can accommodate door or other opening variations in both thickness and width. Even with the simply, yet enhanced mounting arrangement, the construction of the overall frame assembly enables a high fire rating to be obtained. 
     Additional objects, features and advantages of the present invention will become more readily apparent from the following detailed description of preferred embodiments when taken in conjunction with the drawings wherein like reference numerals refer to corresponding parts in the several views. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portion of a partially assembled adjustable door frame constructed in accordance with the present invention; 
         FIG. 2  is an exploded view of the assembly of  FIG. 1 ; 
         FIG. 3  is an exploded view of the connection arrangement for the adjustable door frame of the invention, with the connection arrangement being shown including an optional spacer member; 
         FIG. 4A  illustrates an alternative bracket arrangement for the adjustable frame assembly of the invention; 
         FIG. 4B  is an exploded view of the bracket arrangement of  FIG. 4A ; 
         FIG. 5  is a partial exploded view of an overall frame assembly constructed in accordance with the invention and utilizing the bracket arrangement of  FIGS. 4A and 4B ; 
         FIG. 6  is an enlarged, perspective view of the mounting of one bracket arrangement shown in  FIG. 5 ; 
         FIG. 7  is a side view of the bracket arrangement of  FIG. 6 ; 
         FIG. 8  is an exploded view similar to  FIG. 3  but of a modified frame assembly according to the overall invention; 
         FIG. 9  shows free end structure of a preferred embodiment of the frame assembly; 
         FIG. 10  is a perspective view of a multi-piece shipping support used in connection with a door frame assembly constructed in accordance with the present invention; and 
         FIG. 11  shows an opening in which is mounted the adjustable door frame assembly with the shipping support of  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As will become more fully evident below, the adjustable frame assembly of the invention can be employed to frame out various different construction openings, such as door, window, pass-through and the like type openings commonly found in construction settings. For exemplary purposes, a detailed description will be made in setting forth preferred embodiments for an adjustable door frame assembly. However, the basic principles described can also be applied in connection with other types of openings found in the construction industry. 
     With initial reference to  FIGS. 1 and 2 , an adjustable door frame assembly constructed in accordance with the present invention is generally indicated at  2 . Adjustable door frame assembly  2  is adapted to be mounted within a door opening indicated at  5  which is defined, at least in part, by a wall stud  10  to which is secured, on opposing sides thereof, wall coverings  14  and  15  by means of screws, one of which is indicated at  18 . At this point, it should be noted that wall coverings  14  and  15  can take the form of various wallboard materials, but is generally constituted by gypsum sheetrock. It should also be noted at this point that the main components of door frame assembly  2  take a form corresponding to that known in the art. More particularly, the overall door frame assembly  2  includes hinge jamb, striker jamb and header components, with each of these components being formed from two separate members, i.e., a fixed member and a sliding interconnected member. This type of general adjustable door frame assembly is widely known in the art, such as represented by U.S. Pat. No. 5,187,898 which is incorporated herein by reference. In any case, these general adjustable door frame assembly components are used with walls having varying thicknesses. Of particular concern to the present invention is the manner in which the fixed components of door frame, assembly  2  are mounted and, most importantly, the mounting of at least the fixed member of the hinge jamb component, with the fixed hinge jamb component being shown at  25  in these figures. 
     As depicted, fixed hinge jamb component  25  includes a facer portion  27  that terminates in an in-turned edge  29 . Again, as known in the art, facer portion  27  is adapted to be positioned against one wall covering  15  upon mounting of door frame assembly  2 , while an inside section  32  of hinge jamb component  25  extends adjacent wall stud  10  within door opening  5 . Along inside section  32  is defined a recessed, door receiving portion  33  which leads to a door abutment or stop portion  35 . Door abutment portion  35  leads to a channel or groove  38  defined by an in-turned portion  39  leading to an out-turned portion  40  that terminates at a lip  41 . As shown, lip  41  includes a cut-out section  43  that is established juxtaposed a hinge mounting zone  47  formed in door rebate portion  33 . As should be readily apparent, hinge mounting zone  47  includes a plurality of openings (not separately labeled) and is adapted to mount one end of a hinge for a door associated with door frame assembly  2 , with the door also not being shown in these figures for simplicity. 
     At this point, it should be readily apparent that hinge jamb component  25  will include a plurality of vertically spaced hinge mounting zones  47 . In accordance with the invention, sets of brackets are employed to secure hinge jamb component  25  to wall stud  10  at door opening  5 . Below is provided a detailed description of one set of the brackets associated with hinge mounting zone  47  depicted in  FIGS. 1 and 2 . At the same time, it should be recognized that additional sets of brackets would be employed along the length of hinge jamb component  25  in connection with the overall mounting. Certainly, hinge jamb component  25  of adjustable door frame assembly  2  requires the most rigid and sturdy mounting arrangement of all the door frame components. Therefore, at this point, it should be understood that all of the door frame components can be mounting in a corresponding fashion to that described in detail below, or the striker jamb and header components can be mounted in a more conventional manner. 
     In a first embodiment of the invention, each set of brackets includes two brackets  52  and  53 . In accordance with this preferred embodiment, the first bracket  52  includes an elongated main plate portion  58  from which projects two flange portions  60  and  61 . In one preferred construction, the first bracket  52  is formed by bending a metal plate into a generally L-shaped configuration to establish main plate portion  58  and flange portion  60 , with flange portion  60  extending substantially perpendicular to main plate portion  58 . The second flange portion  61  is provided at a position spaced along main plate portion  58  from first flange portion  60 , with second flange portion  61  also extending substantially perpendicular from main plate portion  58 , but in a direction opposite from first flange portion  60 . As shown, second flange portion  61  is actually part of an angled bracket section including a leg  63  which is welded or otherwise affixed to main plate portion  58  at a position spaced from first flange portion  60  by a section  65  of main plate portion  58 . Therefore, with this configuration, the first and second flange portions  60  and  61  are arranged in spaced, generally parallel planes. The main plate portion  58  of first bracket  52  is formed with a plurality of spaced apertures  67 ,  68  and the second flange portion  61  is also formed with a plurality of spaced apertures  70 ,  71 . 
     The second bracket  53  is fixed to, such as by welding, or integrally formed with the respective fixed frame component  25 . In accordance with a preferred embodiment of the invention, second bracket  53  is made of metal and bent to assume a generally Z-shaped cross-section. In any case, second bracket  53  is formed with at least first and second leg portions  77  and  78 , with the first leg portion  77  extending along frame component  25  and second leg portion  78  projecting from frame component  25 , preferably at a substantially perpendicular angle. In the most preferred form of the invention, the second leg portion  78  has an associated length which is longer than a corresponding length of the second flange portion  61  of first bracket  52 . As shown in its most preferred form, second bracket  53  includes a third leg  79  including spaced slots  81  and  82 . In this form, second bracket  53  is preferably welded to fixed door jamb component  25  along third leg  79 . 
     First bracket  52  is configured to be mounted to wall stud  10  defining door opening  5 , with first flange portion  60  being slipped between an edge of wall stud  10  and the adjacent wall covering  14 . Once first flange portion  60  is appropriately positioned, main plate portion  58  of first bracket  52  will abut and extend along an exposed face of stud  10 . At this point, holes (not shown) are drilled in stud  10  in alignment with the plurality of apertures  67  and  68  in main plate portion  58  of first bracket  52  and mechanical fasteners, such as self-tapping sheet metal screws  85  and  86  (or wood screws for wood stud applications), are used to fixedly secure first bracket  52  to stud  10 . Again, it should be understood that multiple sets of brackets are utilized in the mounting of the door frame components such that one or more additional first brackets would be mounted at this stage in a corresponding manner. In a preferred form of the invention, at least three sets of brackets are employed in connection with mounting hinge jamb component  25 , with the sets of brackets being provided at the level of each door hinge. 
     Once the desired number of first brackets are mounted, the respective fixed frame component  25  is put in place, with facer portion  27  of fixed frame component  25  abutting wall  15  defining door opening  5 . Once fixed frame component  25  is in position, the second leg portion  78  of each of the second brackets  53  will be arranged behind the second flange portion  61  of a respective first bracket  52 . The spacing between the second leg portion  78  and the second flange portion  61  will vary depending on the thickness of wall  10 . Regardless, holes (not labeled) are drilled through second leg portion  78  in alignment with the plurality of apertures  70  and  71  in second flange portion  61 . Thereafter, adjustable connectors, shown in the form of elongated screws  90  and  91 , are inserted into the plurality of apertures  70  and  71  and threaded into second leg portion  78 . Without a threaded attachment to second flange portion  61 , tightening of screws  90  and  91  causes fixed frame component  25  to be drawn against the surface of wall  15 , thereby adjusting a distance between first flange portion  60  and facer portion  27  in order to securely attaching hinge jamb component  25  to wall  10 . Once all the fixed frame members are secured, preferably in a corresponding manner to the fixed hinge jamb member  25  as described, the other frame members can be slid into place and joined by the tongue and groove connections in a manner known in the art. 
     In further accordance with the present invention as shown in  FIG. 3 , an optional spacer plate  95  can be installed between second leg portion  78  and second flange portion  61  in order to alter the width of the overall door frame assembly  2 , thereby accommodating various width tolerances for door opening  5 . In one preferred embodiment, the second leg portion  78  and spacer plate  95  are preferably pre-formed with spaced holes  97 ,  98  and  99 ,  100  respectively, which can be aligned to receive mechanical fasteners (not shown) to fix spacer plate  95  as an extension of second leg portion  78 . Thereafter, spacer plate  95  can be interconnect to second flange portion  61  in a manner directly corresponding to that described above with respect to second leg portion  78 . At this point, it should be noted that one set of holes  97 - 100 , such as holes  99  and  100 , could be slotted to allow relative adjustment between spacer plate  95  and second leg portion  78  to establish a variable length extension is accommodate potential variations is opening widths. In any case, this potential variation will be discussed further herein. 
     With particular reference to  FIGS. 4 and 4B , a second embodiment of the invention will now be described wherein bracket  52  is replaced by a reconfigured bracket  152 . As illustrated, bracket  152  includes an elongated main plate portion  158  from which projects two flange portions  160  and  161 . In the most preferred form of this embodiment of the invention, bracket  152  if formed by bending a metal plate into a generally L-shaped configuration to establish main plate portion  158  and flange portion  160 , with flange portion  160  extending substantially perpendicular to main plate portion  158 . Instead of being a solid, generally rectangular-shaped plate, flange portion  160  preferably includes a plurality of spaced teeth members  160 ′. 
     As clearly illustrated, second flange portion  161  is provided at a position spaced along main plate portion  158  from first flange portion  161 , with second flange portion  161  also extending substantially perpendicular from main plate portion  158 , but in a direction opposite from first flange portion  160 . As clearly shown in  FIG. 4B , second flange portion  161  is actually part of an angled bracket section including a leg  163  which is welded or otherwise affixed to main plate portion  158  at a position spaced from first flange portion  160  such that first and second flange portions  160  and  161  are arranged in spaced, generally parallel planes. In addition to apertures  167  and  168  which generally correspond to apertures  67  and  68  of the first embodiment of the invention, main plate portion  158  of bracket  152  is provided with additional apertures  167 ′,  167 ″,  168 ′ and  168 ″. In addition, second flange portion  161  is formed with a plurality of spaced apertures  170  and  171 , which are shown to preferably take the form of slots. 
     As clearly shown in these figures, second flange portion  161  is preferably bent along line  180  relative to leg  163 , with leg  163  including cut lines, such as that indicated at  182 , in order to establish projecting tabs  184  and  185  on second flange portion  161 . To accommodate tabs  184  and  185 , main plate portion  158  is formed with opposing cut-outs  186  and  187  between apertures  167 ,  168  and  167 ′,  168 ′ respectively. When assembling the overall bracket  152 , leg  163  is positioned on main plate portion  158  with tabs  184  and  185  projecting into cut-outs  186  and  187 . In addition, openings  190  and  191  formed in leg  163  are aligned with apertures  167 ′ and  168 ′ respectively. At this point, it is preferable to weld, such as by spot welding, leg  163  to main plate portion  158  to achieve the assembly shown in  FIG. 4A , with the overall bracket  152  being interchangeably used with bracket  152  of the first embodiment. Finally, in one preferred form of the invention, second flange portion  161  is also provided with a hole  192  as another potential attachment point. 
       FIG. 5  illustrates an assembly similar to that set forth in  FIG. 1  of an overall frame assembly  2 ′ which actually incorporates the multiple brackets  152 . Preferably, for a door framing system, brackets  152  would be mounted at hinge locations in a manner directly corresponding to that of  FIGS. 1 and 5  such that teeth  160 ′ are arranged between wall stud  10  and, for instance, wall covering  14 . However, in addition to this overall bracket arrangement located at the hinges, it is also possible to utilize such an arrangement throughout the overall periphery of the door frame assembly, and even between the hinges on one side of the assembly.  FIG. 5  illustrates such an arrangement wherein a bracket combination  53 ,  152  is employed a distance below the hinge area. In this particular arrangement, bracket  152  is rotated 180° and mounted between stud  10  and wall covering  15 . Therefore, it is possible to reverse the direction or positions of the bracket assembly in order to further enhance the structural integrity and rigidity of the overall assembly. 
       FIGS. 6 and 7  illustrate a preferred mounting for these auxiliary or reversed brackets which utilize spacers  95  in conjunction with supporting an end of main plate portion  158  which is spaced from flange portion  160 . More specifically, in accordance with this aspect of the invention, out-turned portion  40  is lanced so as to establish a cut-out illustrated at  200 . The lanced portion of out-turned portion  40  establishes a first cantilevered leg portion  201  and a second cantilevered leg portion  202 . As shown in these figures, cantilevered leg portion  201  extends at an angle from out-turned portion  40 , while leg portion  202  is arranged generally parallel to out-turned portion  40 . A screw  210  is used to threadably attach leg portion  202  to main plate portion  158 , such as through aperture  167 ″. 
     With this overall arrangement, the reversing of either bracket  52  or bracket  152  can enable the overall jamb assembly to be firmly mounted at each of wall coverings  14  and  15 . The number of mounting brackets arrangements on each side can certainly vary with the size of the opening and the degree of rigidity desired, with the most preferred embodiment of a door assembly employing at least three brackets on the hinge jamb side, with two of the brackets located directly at the hinge as shown in  FIG. 1  and another reversed bracket intermediate the upper and lower hinge located brackets as illustrated in  FIG. 5 . 
     As indicated above, door abutment portion  35  defines a channel  38  between in-turned portion  39  and out-turned portion  40 . In order to complete the overall assembly, a facer member  225  is provided as shown in  FIG. 5 , with facer member  225  including a facer portion  227  and an in-turned edge portion  229  in a manner analogous to facer portion  27  and in-turned edge  29  discussed above. In addition, facer member  225  includes a leg portion  240  which adapted to be slidably received within channel  38 . Basically, once fixed hinge jamb component  25  is mounted in the manner set forth in  FIG. 1 , leg portion  240  of facer portion  225  can be slid into a respective channel  38  until in-turned edge portion  229  abuts wall covering  14 . In the most preferred embodiment of the invention, leg portion  240 , being a non-load bearing member, is only frictionally retained within channel  38 , thereby greatly enhancing the assembly and adjustability of the overall system. To enhance this frictional attachment in accordance with the invention, a plurality of high friction zones are established along the length of leg portion  240  as indicated at  245 . In the most preferred embodiment, high friction zones  245  are defined by adhesively secured sandpaper or emery cloth pieces that are folded about leg portion  240  and provide a secure contact with both in-turned portion  39  and out-turned portion  40  for the final assembly. 
     As indicated above, spacer plate  95  functions to accommodate varying widths of openings in which the adjustable frame assembly of the invention can be mounted. Although it is possible to use different size spacer plates  95  to accommodate for varying widths, another embodiment of the invention employs a spacer plate  195  having holes  99 ′ and  100 ′ in the form of slots as shown in  FIG. 8 . With this arrangement, the spacing between fixed component  25  and the opening can be readily adjusted and then spacer plate  195  can be secured to second bracket  53  in a desired location such as through the use of threaded fasteners (not shown). It should be readily understood that other structural variations can be employed. For instance, a first bracket  252  can be readily constructed by having a second flange portion  261  that is formed by a bent section of a main plate portion  258  as also shown in  FIG. 8 . Furthermore, this figure shows first bracket  252  to include end teeth  160 ″ and an elongated central tooth  160 ′″. 
     Further illustrated in  FIG. 9  is the potential inclusion of a reinforcing insert  300  having substantially planar but offset body portions  305  and  306 , along with an end upright  308  and a central upright  310 . Basically, reinforcing insert  300  is preferably utilized in connection with frame component  25  being a door opening such that each opposing frame component  25  includes a respective free end  325  into which reinforcing insert  300  is positioned and secured, such as by welding; to provide for structural reinforcement at the location of free end  325 , particularly for use in connection with hinges and the additional force placed on the first frame component  25  when attaching the second frame component  225 . That is, in connection with a door assembly, the overall frame would be generally an inverted U-shape (illustrated in  FIG. 11 ) and the upper crosspiece of the U-shape would provide substantial structural reinforcement for the attachment of the second frame member  225  in this location, but reinforcing insert  300  would be utilized to provide additional support at each free end  325 . As additionally shown in  FIGS. 9-11 , again particularly in connection with a U-shaped door frame having free ends  325 , it is preferred to provide each free end  325  with an in-turned tab  328 . In the most preferred form of the invention, tab  328  is simply formed by bending an extension of stop or abutment portion  35 , while also providing a series of perforations  330  along the bend seam. Tabs  328  are utilized in combination with a shipping support  340  (best shown in  FIGS. 10 and 11 ) which interconnects the free ends  325  of the U-shape frame to provide enhanced support for shipping and storage. Obviously, such an arrangement would not be necessary in connection with a rectangular or square window frame constructed in accordance with the present invention but is quite advantageous in connection with a U-shaped door frame. In any case, as shown, shipping support  340  is established by a pair of nesting U-shaped channels  342  and  344 , each of which includes a base  350  and upstanding walls  352  and  353 . Upstanding walls  352  and  353  are provided with aligned apertures  360  which are adapted to receive fasteners  370  in order to establish a desired length for shipping support  340 . The ends of shipping support  340  are provided with flanges  380 , each of which is secured to a respective tab  328  such as by welding. After a door frame constructed in accordance with the present invention is mounted, fasteners  370  can be removed and each U-shaped channel  342 ,  344  pivoted up and down in order to force a respective tab  328  to snap off from a respective free end  325  adjacent perforations  330  to establish a finished doorway portal. 
     With the above construction, it should be readily apparent that the adjustable frame assembly of the invention can be assembled in an efficient and sturdy manner, while accommodating door opening variations in both thickness and width. Again, although one preferred embodiment of the invention is associated with an adjustable door frame assembly, the overall invention is directed to an adjustable frame assembly for various building openings such that, instead of defining an opening for a door, the assembly could be readily utilized within a building to establish an interior window or other closable opening. Basically, the mounting of the frame components remain the same between the various different uses, although the actual configuration of the frame components could change. For instance, in the case of framing an interior window opening, the region at door abutment or stop portion  35  would be reconfigured to accept and retain one or more panes of glass. Importantly, the invention provides an extremely effective way to establish a fire rated building opening while utilizing a frame assembly that is easy to install and which can be readily adjusted to accommodate varying thicknesses of the walls in which the openings are formed. Therefore, although described with reference to preferred embodiments of the invention, it should be readily understood that various changes and/or modifications can be made to the invention without departing from the spirit thereof. Instead, the invention is only intended to be limited by the scope of the following claims.