Patent Publication Number: US-7213371-B1

Title: Closure clip for pre-hung doors

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to pre-hung doors, and, in particular to a closure clip that will secure a pre-hung door in a closed and aligned position during shipping, delivery, and installation. 
   2. Description of Related Art 
   Prefabricated and pre-hung door and door frame units have become standard for most building construction situations. Such doors are generally preassembled and aligned or squared, i.e., pre-hung, within the frame, or jamb, at the manufacturing facility. 
   However, during transshipment and in installation pre-hung doors may become misaligned. In an assembled pre-hung door, the hinges generally secure the door to the hinge jamb and hold it in place, while the other jamb, or strike jamb, though attached to the head jamb, is not otherwise secured relative to the door. Thus, the strike jamb and the head jamb may move relative to the door and hinge jamb during transshipment or installation, thereby becoming misaligned. 
   For this reason various means have been devised for reversibly fixing doors in an aligned or pre-hung position. The simplest such means has been the use of one or two dual headed nails driven through the back of the strike jamb into the free edge of the door, thereby holding the door and the strike jamb in fixed relation. 
   In U.S. Pat. Nos. 5,159,782, 5,722,203, 5,787,639, and 6,170,198, various aids have been provided for fastening a pre-hung door assembly and maintaining its alignment during transshipment and installation. These disclosed aids are similar in that they comprise at least a first piece received in the back of the strike jamb and a second piece received in the door knob bore with a post extending through the lockset bore of the door. 
   U.S. Pat. No. 5,562,315, discloses a two-piece device for securing and retaining a pre-hung door that comprises a shaped cylindrical plug configured to fit closely in the lockset bore of a door. The plug can be moved within the bore so that a configured end engages a bore of the strike jamb, thus securing the door in a closed position. Slots provided in the configured end of the plug receive a retention tab that is inserted through the door reveal, securing the plug in position. 
   In using such multiple piece devices multiple steps are required to align the door components and utilize the interacting parts to fasten the assembly together. The pre-hung door assembly is therefore complicated by the requirement of attaching the multiple pieces to each other, and further, at the time of installation of the pre-hung door assembly the pieces must be separated prior to installing the pre-hung door assembly. Once they have been separated the door may becoming misaligned by handling during the installation stage. 
   One-piece closures have also been proposed for use in assembling pre-hung doors. In U.S. Pat. Nos. 4,483,101, and 6,357,181, similar one-piece fastening devices are disclosed comprising an elongated strap formed of a flexible material. A cylindrical member projecting from one end of the straps is adaptable for seating in the lockset bore. In both devices the flexible strap is extended from door knob bore across the face of the door and the marginal edge of the jamb. A terminal region of the strap is pulled over a portion of the jamb face for stapling to the strike jamb. U.S. Pat. No. 5,209,017, discloses a rigid polymeric one-piece retaining device for attachment to a pre-hung door assembly. The device includes a planar surface for placement against the door face and includes a cylindrical insert for placement within the door knob bore or opening in the door face. A stabilizer is attached perpendicularly to the device for location in the door reveal to assist in spacing and holding the door in a fixed position relative to the frame. The planar surface is stapled to the strike jamb by the installer. 
   One-piece retaining devices of the prior art have no mechanism for precisely and simultaneously aligning the door and strike jamb, thus demanding care and precision from the installer during assembly to be certain that the door and strike jamb are properly aligned and spaced before stapling. Additionally, in the flexible one-piece devices, stretching and flexing of the material during transshipment and installation can allow the door and jambs to move relative to each another, causing the door to come out of proper alignment. 
   Thus, there remains a need for a door fastening and closure device that reliably, easily and reversibly maintains a pre-hung door in proper alignment through shipment and installation. 
   SUMMARY OF THE INVENTION 
   The present invention provides a closure clip for use in a pre-hung door assembly of the type having a door frame comprising a hinge jamb, a strike jamb and a header jamb connecting the hinge and strike jambs, where the door comprises a hinged edge mounted to the hinge jamb and a free edge opposing the strike jamb, with a door knob bore formed in a face of the door in communication with a lockset bore formed in the free edge. In such an assembly, the space between the free edge and the lock jam defines a door reveal where the lockset bore is generally aligned with a transverse jamb bore located within the strike jamb. 
   The closure clip particularly comprises a barrel, a barrel extension and a generally rigid fastening tab connected to the barrel opposite the barrel extension, the fastening tab having a reveal spacer tab and a jamb secure tab, whereby in operably fastening the closure clip to the pre-hung door assembly the barrel is inserted within the lockset bore while the barrel extension is inserted within the transverse jamb bore, the fastening tab extends from the door knob bore and across a portion of a face of the door and across a portion of the strike jamb, the reveal spacer tab is inserted in the door reveal and the jamb secure tab overlays a surface of the strike jamb opposite the door reveal and overlaying the transverse jamb bore. The barrel extension has a generally elliptical cross section 
   The closure clip may further comprise a flex joint disposed generally between the barrel and the fastening tab to provide movement of the fastening tab relative to the barrel. 
   The closure clip barrel may be sized to have a diameter slightly less than the diameter of a standard lockset bore and the barrel extension may have a diameter slightly less than the diameter of a standard transverse jamb bore. 
   Alternatively, the closure clip barrel extension may be sized to fit snugly within a standard transverse jamb bore. 
   In one embodiment the jamb secure tab comprises a terminal spacer ridge for resting on a surface of a strike jamb opposite the door reveal. 
   The closure clip preferably comprises a reveal lock formed by a space located between the barrel and the barrel extension. The reveal lock is for accepting the spacer reveal tab. More preferably, the reveal spacer tab has a tapered end for directing positioning of the reveal spacer tab into the reveal lock 
   The barrel extension preferably comprises a ridge along the edge if the reveal lock forming a jamb stop for stopping the barrel extension at a predetermined depth and thereby helping in positioning the barrel extension within the transverse jamb bore. 
   These and other features and advantages of this invention are described in, or are apparent from, the following detailed description of various exemplary embodiments of the devices and methods according to this invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein: 
       FIG. 1  is a side view of the closure clip. 
       FIG. 2  is a partially cut away view of the closure clip as used to fasten a pre-hung door assembly. 
       FIG. 3  is side elevational view of a first closure clip embodiment. 
       FIG. 4  is a perspective view of a first closure clip embodiment. 
       FIG. 5  is side elevational view of a second closure clip having a longer fastening tab. 
       FIG. 6  is a perspective view of the second closure clip embodiment. 
       FIG. 7  is side elevational view of a third closure clip embodiment having a thinned section connecting the jamb secure tab to the fastening tab for ease of removal of the closure clip from an installed door assembly. 
       FIG. 8  is a perspective view of the third closure clip embodiment. 
   

   Corresponding reference numerals will be used throughout the several figures of the drawings. 
   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The following detailed description illustrates the invention by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the invention, and describes what we presently believe is the best mode of carrying out the invention. 
   A typical pre-hung door assembly includes a door mounted in a frame. As is known, the frame includes a hinge jamb to which the door is mounted by hinges, a head jamb, and a strike jamb where the door lock assembly interacts with the frame to secure the swinging end of the door. The head jamb extends across the top of the door to connect the hinge and strike jambs. 
   The door of a pre-hung door assembly conventionally has a hinged edge mounted to the hinge jamb and a free edge opposing the strike jamb. A door knob bore formed in a surface of the door is in communication with a lockset bore formed in the free edge of the door, the latter opening to the strike jamb. The lockset bore is sometimes referred to as a latch bore or edge bore. The lockset bore provides a lock or latch opening and is adaptable for accommodating a suitable lock bolt or door latch (not shown). 
   The door knob bore, sometimes referred to as the body bore or cross bore, is conventionally about 2 and ⅛ inch in diameter, though often substantially smaller. The door knob bore is adaptable for accommodating a door knob or lock body. The longitudinal axis of the door knob bore is transverse to the face of the door and also transverse to the longitudinal axis of the lockset bore. 
   The space between the free edge of the door and the strike jam defines the door reveal. The lockset bore is aligned with a transverse jamb bore located within the strike jamb and directly across the door reveal from the lockset bore, thereby providing a hole in the strike jamb which in the completed door accepts a bolt from the lockset assembly, thereby securing the door in a closed relation to the strike jamb. 
   Referring now specifically to the drawings, there is shown in  FIG. 1  a closure clip  10  of the invention. The closure clip  10  provides a one-piece unit that is easily inserted in the lockset bore and that can remain fastened during transshipment and installation of the pre-hung door assembly in a doorway. The door is thereby maintained closed and in proper alignment with the door jambs, and, in particular, with the strike jamb. 
   The closure clip  10  generally comprises a barrel  12 , a barrel extension  14  and a generally rigid fastening tab  16  connected to the barrel  10  opposite the barrel extension  12 . The fastening tab  16  forms a semi-rigid structure that extends back and over the barrel  12  towards the barrel extension terminal end  18 . The fastening tab further comprises a reveal spacer tab  20  and a jamb secure tab  22 . 
   By semi-rigid structure, it is meant that the fastening tab  16  is generally of a rigid material sufficiently thick to withstand the stress caused by door movement during shipping and handling. Because of the rigid nature of the material forming the fastening tab  16 , the closure clip reduces sag and maintains the door reveal through point of sale and even installation. When produced of a reasonably rigid plastic material, the fastening tab  16  may be formed to on order of about 11/100 of inch or less in thickness. The fastening tab will also be provided with a small amount of inherent flexibility, however, largely derived from the nature of the plastic material. This is desirable in that some flexibility in the generally rigid structure makes the closure clip easier to insert into the lockset bore and push into fastening fit with the strike jamb. 
   The closure clip  10  also preferably comprises a flex joint  24  disposed generally between the barrel  12  and the fastening tab  16  to provide further ease the movement of the fastening tab relative to the barrel. The flex joint  24  provides additional flexibility to the fastening tab  16  allowing easy insertion of the semi-rigid closure clip into as lockset hole. The flex joint  24  may be produced by providing or fabricating the closure clip  10  with a thinned plastic region at the fastening tab  16 , or by cutting, scoring or other means known to the art. 
   The barrel  12  and barrel extension  14  may have a generally elliptical cross section, or may be of any other suitable shape for insertion within the lockset bore and the transverse jamb bore, respectively, of a pre-hung door assembly. 
   As best seen in reference to  FIG. 2 , the closure clip  10  is fastened to a pre-hung door assembly  28  to stabilize the reveal  30  formed between the door  32  to the strike jamb  34  (shown partially cut away in  FIG. 2  to reveal the placement of the closure clip  10  within the various components of the assembly  28 ). The closure clip  10  aligns the free edge  36  of the door with the strike jamb  34 , first of all by aligning the lockset bore  38  of the door  32  with the transverse jamb bore  40  of the strike jamb  34 . The barrel extension  14  is inserted through the lockset bore  38  from the door knob bore  42 , and pushed through the lockset bore  38  until it is fitted into the transverse jamb bore  40  with the barrel  12  occupying the lockset bore and the barrel extension  14  occupying the transverse jamb bore  40 . 
   A transverse region  44  of the fastening tab  16  most proximal to the flex joint  24  spans that portion of door knob bore  42  that extends from the lockset bore  38  to the door surface  46 . An elongated region  48  of the fastening tab then spans that portion of the door surface  46  between the door knob bore  42  and the free edge  36  and continues across a portion of the outer strike jamb surface  50  flush with the door. With the closure clip  10  in fastening position this elongated region  48  is disposed generally parallel to the longitudinal axis of the barrel  12 . A raised section  52  in the transverse region  44  of the fastening tab  16  provides additional positive placement of the closure clip  10  within the lockset hole  38 . 
   Further in reference to  FIG. 2 , the reveal spacer tab  20  fits into the door reveal  52  while the jamb secure tab  22  overlays the outer surface  54  of the strike jamb  34  opposite the door reveal  30 , preferably overlaying the transverse jamb bore  40 . 
   The door reveal  30  allows free swinging of the door  32  as it opens and closes, and is conventionally about 3/32 of an inch. The reveal spacer tab  20  is preferably of nearly the same thickness, about 11/100 of an inch. Upon installation of the closure clip  10 , the reveal spacer tab  20  is inserted into this reveal  30 , thereby assisting in maintaining alignment of the assembly  28  during transshipment and installation. 
   The barrel  12  is sized to have a diameter slightly less than the diameter of a standard lockset bore  38  and the barrel extension  14  may be similarly sized to have a diameter slightly less than the diameter of a standard transverse jamb bore  40 . Alternatively, the barrel extension  14  may be sized to fit more snugly within a standard transverse jamb bore  40 . 
   The closure clip preferably comprises a reveal lock  56 , i.e., a partial space formed between and separating the barrel  12  and the barrel extension  14 , which will be aligned with the door reveal  30  in operation. The reveal lock  56  accepts the spacer reveal tab  20  during fastening of the closure clip  10 , with the various components thereby operating as a unit to fasten and secure a pre-hung door assembly  28 . 
   The one-piece design for the closure clip  10  allows it to be rapidly and securely fastened to a pre-hung door assembly  28 . In fastening a door  32  and strike jamb  34  using the closure clip  10 , the user holds the closure clip  10  by the fastening tab  16 , slightly bending the fastening tab  16  at the flex joint  24 . The barrel  12  is then pushed through the door knob hole  42  and lockset hole  38 , until the barrel extension  14  is fitted into the transverse jamb bore  40  of the strike jamb  34 . The reveal spacer tab  20  is then pushed down through the door reveal  30  and into the reveal lock  56 , while the jamb secure tab  22  overlays the strike jamb  34  along its outer surface  54 . While holding the jamb secure tab  22  in place, a single staple (not shown) may be placed through the jamb secure tab  22  into the outer jamb surface  54 . Where the transverse jamb bore  40  extends the width of the strike jamb  34 , the jamb secure tab  22  may be stapled directly into the end  18  of barrel extension  14 , in which case the entire assembly is accomplished with no staples inserted into either the door  32  or strike jamb  34 . 
   In one embodiment the jamb secure tab  22  comprises a terminal spacer ridge  58  for resting on the outer surface  54  of the strike jamb  34 . This rounded ridge  58  raises the jamb secure tab  22  for ease of removal by the door installer, such as by a screwdriver inserted into the space  60  formed between the outer surface  54  of the strike jamb  34  and the jamb secure tab  22 . 
   A stop tab  62  is provided on the barrel extension  14  towards the reveal lock  56  to prevent the barrel extension  14  from going too far into the transverse jamb bore  40 , and generally provides proper positioning of the closure clip  10  so that the reveal lock  56  will properly align within the reveal  30 . 
   The reveal spacer tab  20  may be provided with a tapered end  64  for directing the positioning of the reveal spacer tab  20  into the reveal lock  56 . 
   As a one-piece unit, the closure clip  10  may be simply manufactured, preferably formed of a semi-rigid plastic or other suitable material, for instance a polyethylene, polypropylene or polystyrene, and can be easily fabricated by injection molding using either virgin or recycled plastic. As is seen with reference to  FIGS. 3 through 8 , the closure clip is designed with vertical and horizontal ribs on the barrel  12  and barrel extension  14 , to reduce the quantity of material needed to fabricate the closure clip  10 , thereby substantially reducing the weight of the closure clip  10 . Such ribs are commonly provided to add strength in lighter weight plastic objects. 
   The closure clip  10  provides a low-profile clip in the form of a single unitary piece that is easier to install and remove than prior art fastening aids. The closure clip  10  can be used on inside or outside doors to reduce sag and maintain the door&#39;s reveal through point of sale and in installation. The closure clip  10  can be used on inside or entry doors, and as it is bilaterally symmetrical it can be used equally well with both right hand and left hand swing doors. The closure clip  10  is easier than prior fastening devices to install and remove from a pre-hung door assembly. 
   The closure clip  10  may be produced in different sizes for use with various commonly employed interior and entry doors.  FIGS. 3 and 4  show a closure clip  10  adapted for use with commonly sized interior doors, such as interior flat jamb doors with 2⅜″ backset with left or right hand swing and exterior doors with 2⅜″ backset with left or right hand swing. In a closure clip  10  adapted for such doors the barrel  12  and barrel extension  14  are designed to span a distance of approximately 1.89 inches, while the transverse region  44  of the fastening tab  16  can be designed to span 0.57 inch. The elongated region  48  of the fastening tab  16  will span a distance of approximately 1.44 inches from the transverse region  44  to the reveal spacer tab  20 , and 0.61 inches from the reveal spacer tab  20  to the jamb secure tab  22 . 
   The closure clip  10  can also be produced for use with exterior doors with 2¾″ backset with left or right hand swing ( FIGS. 5 and 6 ). For a closure clip  10  adapted for the larger backset doors the barrel  12  and barrel extension  14  together can be designed to span a distance of approximately 2.27 inches, while the transverse region  44  of the fastening tab  16  is designed to span approximately 0.75 inch. The elongated region  48  of the fastening tab  16  will span a distance of approximately 1.78 inches from the transverse region  44  to the reveal spacer tab  20 , and a similar approximately 0.61 inches from the reveal spacer tab  20  to the jamb secure tab  22 . It will be observed that in  FIGS. 5 and 6  the barrel comprises an additional rib over that observed for the closure clip shown in  FIGS. 3 and 4 . 
   The closure clip  10  forms a low profile on the outside of the strike jamb  34  where the jamb secure tab  22  is connected, and for this reason in many applications it may be simpler to leave the closure clip  10  in during installation of the pre-hung door assembly  28 , essentially forming a temporary latch until the door has been installed. In such cases, the closure clip  10  can be removed after door installation by cutting the fastening tab  16  at the outer strike jamb surface  50 , preferably as close to the jamb secure tab  22  as possible. In this alternative use, the closure clip  10  is treated as a disposable item, with the advantage that is can be left in place until the door installation is complete, with the door  32  thereby maintained in its proper aligned position through the completion of the installation process. To then remove the barrel  12  from the lockset bore  38 , the jamb secure tab  22  is cut away from the remainder of the closure clip  10 . It may even remain permanently attached to the outer surface  54  of the strike jamb  34  in the installed door. 
   In one version of the closure clip a thinned section  66  is provided along the fastening tab  16  between the jamb secure tab  22  and the reveal spacer tab  20  ( FIGS. 7 and 8 ). The dimensions of this closure clip  10  are otherwise similar to that described for the closure clip shown in  FIGS. 3 and 4 . The closure clip shown in  FIGS. 7 and 8  can be used with interior split jamb door assemblies having a 2⅜″ backset with left or right hand swing. The thinned section version is particularly useful for split jamb assemblies where the casing is installed on the jamb prior to shipping. The thinned section is able to fit under the trim piece and is easily removed, as thinning in this region of the fastening tab  16  both allows this tab to fit under the casing and makes it easier to cut the closure clip  10  free from the jamb secure tab  22 , before or after installation. 
   Alternatively, the closure clip  10  may be reusable, in which case it will preferably be removed prior to installation of the pre-hung door assembly  28 . This is accomplished simply by removing the staple securing the jamb secure tab  22  to the outer surface  54  of the strike jamb  34 , and then gently pulling the barrel  12  back through the lockset bore. 
   While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of this invention.