Patent Publication Number: US-11655665-B2

Title: Jamb-hung secondary door and method of installation

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of U.S. patent application Ser. No. 17/111,986 entitled “JAMB-HUNG SECURITY DOOR AND METHOD OF INSTALLATION” to Chavez that was filed on Dec. 4, 2020, and claims the benefit of the filing date of U.S. Provisional Patent Application 62/943,686 entitled “JAMB-HUNG SECURITY DOOR AND METHOD OF INSTALLATION” to Chavez that was filed on Dec. 4, 2019, the disclosures of both of which are hereby incorporated herein by this reference. 
    
    
     TECHNICAL FIELD 
     Aspects of this document relate generally to secondary doors, and more specifically to secondary doors configured to directly couple to the house frame. 
     BACKGROUND 
     Homeowners commonly elect to have two doors installed in any given doorway, with one door being the threshold door and the other door being a secondary door designed to increase airflow or visibility through the doorway. Typically, the secondary door is attached to the door frame of the threshold door using fasteners that are accessible from outside the secondary door. This makes the secondary door removable from outside the secondary door, even when it is closed and locked. What is needed is a secondary door with increased security that cannot be removed when the secondary door is closed and locked. 
     SUMMARY 
     Aspects of this document relate to a method of installing a combination door unit into a threshold of a house, the method comprising placing a combination door unit within a threshold opening of a house, wherein the combination door unit fills the threshold opening and comprises a door frame having a head and two jambs, a threshold door hingedly coupled to a first jamb of the two jambs, and a secondary door having a mounting frame, wherein the secondary door is hingedly coupled to the mounting frame through a plurality of slip hinges each having a base and a tube, and the mounting frame is coupled to the door frame by a first plurality of fasteners, wherein the threshold opening is surrounded by a plurality of house frame studs, and, when the combination door unit is placed within the threshold opening, the mounting frame, the door frame, and the plurality of house frame studs are aligned, leveling the combination door unit, wherein the step of leveling the combination door unit comprises the step of inserting a plurality of shims between the plurality of house frame studs and the combination door unit, removing the secondary door from the combination door unit, wherein the step of removing the secondary door comprises the step of lifting each tube of the plurality of slip hinges off of a corresponding base of the plurality of slip hinges, driving a second plurality of fasteners through the mounting frame, through the door frame, and into the house frame studs, wherein each of the second plurality of fasteners is longer than each of the first plurality of fasteners, is driven spaced apart from each adjacent fastener of the second plurality of fasteners around the perimeter of the combination door unit, and is driven into one of the house frame studs to a depth of at least ½ inch, and replacing the secondary door on the combination door unit, wherein the step of replacing the secondary door comprises the step of placing each tube of the plurality of slip hinges onto the corresponding base of the plurality of slip hinges. 
     Particular embodiments may comprise one or more of the following features. The mounting frame may have at least three sides each comprising a mounting flange, wherein the mounting flanges are configured to overlap with the corresponding head and two jambs of the door frame, the step of driving the second plurality of fasteners through the mounting frame comprising the step of driving the second plurality of fasteners through the mounting flanges of the mounting frame. The mounting frame may be formed of metal. The step of driving the second plurality of fasteners may comprise the steps of driving a first portion of the second plurality of fasteners through the first jamb, driving a second portion of the second plurality of fasteners through a second jamb of the two jambs, and driving a third portion of the second plurality of fasteners through the head of the door frame. 
     Aspects of this document relate to a method of installing a combination door unit into a threshold of a house, the method comprising placing a combination door unit within a threshold opening of a house, wherein the threshold opening is surrounded by a plurality of house frame studs, the combination door unit comprising a door frame having a head and two jambs, a threshold door hingedly coupled to a first jamb of the two jambs, and a secondary door having a mounting frame, wherein the secondary door is hingedly coupled to the mounting frame, and the mounting frame is coupled to the door frame by a first plurality of fasteners, wherein, when the combination door unit is placed within the threshold opening, the mounting frame, the door frame, and the plurality of house frame studs are aligned, leveling the combination door unit, and driving a second plurality of fasteners through the mounting frame, through the door frame, and into the house frame studs, wherein each of the second plurality of fasteners is driven into one of the house frame studs to a depth of at least ½ inch. 
     Particular embodiments may comprise one or more of the following features. The secondary door may be coupled to the mounting frame through a plurality of slip hinges. The step of leveling the combination door unit may comprise the step of inserting a plurality of shims between the plurality of house frame studs and the combination door unit. The method may further comprise removing the secondary door from the combination door unit prior to driving the second plurality of fasteners and replacing the secondary door on the combination door unit after the step of driving the second plurality of fasteners. The step of driving the second plurality of fasteners may comprise the step of spacing apart the second plurality of fasteners around the perimeter of the combination door unit. The mounting frame may have at least three sides each comprising a mounting flange, wherein the mounting flanges are configured to overlap with the corresponding head and two jambs of the door frame, and the step of driving the second plurality of fasteners through the mounting frame may comprise the step of driving the second plurality of fasteners through the mounting flanges of the mounting frame. The step of driving the second plurality of fasteners may comprise the steps of driving a first portion of the second plurality of fasteners through the first jamb, driving a second portion of the second plurality of fasteners through a second jamb of the two jambs, and driving a third portion of the second plurality of fasteners through the head of the door frame. 
     Aspects of this document relate to a method of installing a combination door unit into a frame of a house, the method comprising placing a combination door unit within a threshold opening of a house, wherein the threshold opening is surrounded by a plurality of house frame studs, the combination door unit comprising a door frame, a threshold door hingedly coupled to the door frame, and a secondary door coupled to the door frame through a mounting frame, wherein, when the combination door unit is placed within the threshold opening, the mounting frame, the door frame, and the plurality of house frame studs are aligned, and driving a second plurality of fasteners through the mounting frame, through the door frame, and into the house frame studs, wherein each of the second plurality of fasteners extends into one of the house frame studs. 
     Particular embodiments may comprise one or more of the following features. The secondary door may be coupled to the mounting frame through a plurality of slip hinges. The method may further comprise the step of leveling the combination door unit, wherein the step of leveling the combination door unit comprises the step of inserting a plurality of shims between the plurality of house frame studs and the combination door unit. The method may further comprise removing the secondary door from the combination door unit prior to driving the second plurality of fasteners and replacing the secondary door on the combination door unit, after the step of driving the second plurality of fasteners. The step of driving the second plurality of fasteners may comprise the step of spacing apart the second plurality of fasteners around the perimeter of the combination door unit. The mounting frame may have at least three sides each comprising a mounting flange, wherein the mounting flanges are configured to overlap with the door frame, and the step of driving the second plurality of fasteners through the mounting frame may comprise the step of driving the second plurality of fasteners through the mounting flanges of the mounting frame. The combination door unit may further comprise a multi-point lock system having a central throw and at least two hooks operatively coupled to a key hole within the secondary door, wherein when the key hole is in a locked position, the central throw and the at least two hooks extend out of the secondary door, and when the key hole is in an unlocked position, the central throw and the at least two hooks are retracted into the secondary door. The step of driving the second plurality of fasteners may comprise the steps of driving a first portion of the second plurality of fasteners through a first jamb of the door frame, driving a second portion of the second plurality of fasteners through a second jamb of the door frame, and driving a third portion of the second plurality of fasteners through a head of the door frame. The mounting frame may be coupled to the door frame by a first plurality of fasteners. 
     The foregoing and other aspects, features, applications, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims. Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their plain, ordinary, and accustomed meaning to those of ordinary skill in the applicable arts. The inventors are fully aware that they can be their own lexicographers if desired. The inventors expressly elect, as their own lexicographers, to use only the plain and ordinary meaning of terms in the specification and claims unless they clearly state otherwise and then further, expressly set forth the “special” definition of that term and explain how it differs from the plain and ordinary meaning. Absent such clear statements of intent to apply a “special” definition, it is the inventors&#39; intent and desire that the simple, plain and ordinary meaning to the terms be applied to the interpretation of the specification and claims. 
     The inventors are also aware of the normal precepts of English grammar. Thus, if a noun, term, or phrase is intended to be further characterized, specified, or narrowed in some way, then such noun, term, or phrase will expressly include additional adjectives, descriptive terms, or other modifiers in accordance with the normal precepts of English grammar. Absent the use of such adjectives, descriptive terms, or modifiers, it is the intent that such nouns, terms, or phrases be given their plain, and ordinary English meaning to those skilled in the applicable arts as set forth above. 
     Further, the inventors are fully informed of the standards and application of the special provisions of 35 U.S.C. § 112(f). Thus, the use of the words “function,” “means” or “step” in the Detailed Description or Description of the Drawings or claims is not intended to somehow indicate a desire to invoke the special provisions of 35 U.S.C. § 112(f), to define the invention. To the contrary, if the provisions of 35 U.S.C. § 112(f) are sought to be invoked to define the inventions, the claims will specifically and expressly state the exact phrases “means for” or “step for”, and will also recite the word “function” (i.e., will state “means for performing the function of [insert function]”), without also reciting in such phrases any structure, material or act in support of the function. Thus, even when the claims recite a “means for performing the function of . . . ” or “step for performing the function of . . . ,” if the claims also recite any structure, material or acts in support of that means or step, or that perform the recited function, then it is the clear intention of the inventors not to invoke the provisions of 35 U.S.C. § 112(f). Moreover, even if the provisions of 35 U.S.C. § 112(f) are invoked to define the claimed aspects, it is intended that these aspects not be limited only to the specific structure, material or acts that are described in the preferred embodiments, but in addition, include any and all structures, materials or acts that perform the claimed function as described in alternative embodiments or forms of the disclosure, or that are well known present or later-developed, equivalent structures, material or acts for performing the claimed function. 
     The foregoing and other aspects, features, and advantages will be apparent to those of ordinary skill in the art from the specification, drawings, and the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Implementations will hereinafter be described in conjunction with the appended drawings, where like designations denote like elements, and: 
         FIG.  1    is a front view of a threshold opening. 
         FIG.  2    is a perspective view of a combination door unit installed within the threshold opening shown in  FIG.  1   . 
         FIG.  3    is a front view of a combination door unit. 
         FIG.  4    is an exploded view of the combination door unit shown in  FIG.  3   . 
         FIG.  5    is an exploded view of the mounting frame of the combination door unit shown in  FIG.  3   . 
         FIG.  6 A  is a bottom view of the combination door unit shown in  FIG.  3    without the secondary door. 
         FIG.  6 B  is a close-up view taken from circle  6 B in  FIG.  6 A . 
         FIG.  7 A  is a perspective view of the combination door unit shown in  FIG.  3    with the secondary door lifted off of the slip hinges. 
         FIG.  7 B  is a close-up view taken from circle  7 B in  FIG.  7 A . 
         FIG.  8    is a process flow chart showing the steps of installing the combination door unit shown in  FIG.  3    into a threshold of a house. 
         FIG.  9 A  is a bottom perspective view of the combination door unit shown in  FIG.  3    with the secondary door opened to show the three-point lock system. 
         FIG.  9 B  is a close-up view taken from circle  9 B in  FIG.  9 A . 
         FIG.  9 C  is a close-up view taken from circle  9 C in  FIG.  9 A . 
         FIG.  10 A  is a front view of the combination door unit shown in  FIG.  3    with the three-point lock system in the locked position. 
         FIG.  10 B  is a close-up view taken from circle  10 B in  FIG.  10 A . 
         FIG.  10 C  is a close-up view taken from circle  10 C in  FIG.  10 A . 
         FIG.  10 D  is a close-up view taken from circle  10 D in  FIG.  10 A . 
         FIG.  11 A  is a front view of the combination door unit shown in  FIG.  3    with the three-point lock system in the unlocked position. 
         FIG.  11 B  is a close-up view taken from circle  11 B in  FIG.  11 A . 
         FIG.  11 C  is a close-up view taken from circle  11 C in  FIG.  11 A . 
         FIG.  11 D  is a close-up view taken from circle  11 D in  FIG.  11 A . 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of implementations. 
     DETAILED DESCRIPTION 
     This disclosure, its aspects and implementations, are not limited to the specific material types, components, methods, or other examples disclosed herein. Many additional material types, components, methods, and procedures known in the art are contemplated for use with particular implementations from this disclosure. Accordingly, for example, although particular implementations are disclosed, such implementations and implementing components may comprise any components, models, types, materials, versions, quantities, and/or the like as is known in the art for such systems and implementing components, consistent with the intended operation. 
     The word “exemplary,” “example,” or various forms thereof are used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” or as an “example” is not necessarily to be construed as preferred or advantageous over other aspects or designs. Furthermore, examples are provided solely for purposes of clarity and understanding and are not meant to limit or restrict the disclosed subject matter or relevant portions of this disclosure in any manner. It is to be appreciated that a myriad of additional or alternate examples of varying scope could have been presented, but have been omitted for purposes of brevity. 
     While this disclosure includes a number of implementations that are described in many different forms, there is shown in the drawings and will herein be described in detail particular implementations with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspect of the disclosed concepts to the implementations illustrated. 
     In the following description, reference is made to the accompanying drawings which form a part hereof, and which show by way of illustration possible implementations. It is to be understood that other implementations may be utilized, and structural, as well as procedural, changes may be made without departing from the scope of this document. As a matter of convenience, various components will be described using exemplary materials, sizes, shapes, dimensions, and the like. However, this document is not limited to the stated examples and other configurations are possible and within the teachings of the present disclosure. As will become apparent, changes may be made in the function and/or arrangement of any of the elements described in the disclosed exemplary implementations without departing from the spirit and scope of this disclosure. 
     The present disclosure discusses a combination door unit  100  configured to be installed within a threshold opening  102  of a frame  104  of a house (not shown). The threshold opening  102  within the frame  104  is illustrated in  FIG.  1   . As shown, the threshold opening  102  is typically surrounded by a plurality of house frame studs  106 , which help to hold the combination door unit  100  in place once installed. 
       FIG.  2    illustrates one embodiment of the combination door unit  100  within the threshold opening  102 . The combination door unit  100  may fill the threshold opening  102 .  FIGS.  3 - 5    illustrate an embodiment of the combination door unit  100 . The combination door unit  100  may comprise a door frame  108 , a threshold door  110 , and a secondary door  112 . In some embodiments, the door frame  108  and the threshold door  110  may already be installed within the threshold opening  102 . In such an embodiment, the combination door unit  100  comprises the secondary door  112 . The door frame  108  has two parallel jambs  114  joined at the top by a head  116 . The threshold door  110  may be hingedly coupled to a first jamb  118  of the two jambs  114 . 
     The secondary door  112  has a mounting frame  120 . In some embodiments, the mounting frame  120  is formed of metal. In a particular embodiment, the mounting frame  120  is formed of aluminum. The mounting frame  120  may be coupled to the door frame by a first plurality of fasteners  122 , such as screws or nails. A plurality of slip hinges  124  may couple the secondary door  112  to the mounting frame  120 . Referring back to  FIG.  2   , when the combination door unit  100  is placed within the threshold opening  102 , the mounting frame  120 , the door frame  108 , and the plurality of house frame studs  106  are aligned. Returning to  FIGS.  3 - 5   , once the combination door unit  100  is completely installed within the threshold opening  102 , a second plurality of fasteners  126 , such as screws or nails, extends through the mounting frame  120 , through the door frame  108 , and into the plurality of house frame studs  106 . The second plurality of fasteners  126  are generally longer, individually, than the individual fasteners of the first plurality of fasteners  122 . In addition, each of the second plurality of fasteners  126  is spaced apart from each adjacent fastener  126  around the perimeter of the combination door unit  100 , and each of the second plurality of fasteners  126  extends into the house frame studs  106  to a depth  128  (see  FIG.  3   ). The depth  128  may be at least ¼ inch, at least ½ inch, at least 1 inch, or at least 1.5 inches. Alternatively, the second plurality of fasteners  126  may extend all the way through the house frame studs  106 . 
     Referring specifically to  FIG.  5   , the mounting frame  120  may have at least three sides  130 . Each side  130  may have a mounting flange  132 . The mounting flange  132  is a thin extension from the mounting frame  120  and is configured to overlap with the corresponding head  116  and two jambs  114  of the door frame  108  (see  FIG.  6 B ). In embodiments having mounting flanges  132 , the second plurality of fasteners  126  extends through the mounting flanges  132  to extend through the door frame  108  and into the plurality of house frame studs  106 . In addition, the first plurality of fasteners  122  extends through the mounting flanges  132  to couple the mounting frame  120  to the door frame  108 .  FIGS.  6 A- 6 B  further illustrate the mounting flange  132  overlapping with the door frame  108 . 
       FIGS.  7 A- 7 B  illustrate the function of the plurality of slip hinges  124 . Each slip hinge  124  comprises a base  134  and a tube  136 . The base  134  has a prong  138  which extends upward from the base  134 . The prong  138  is sized to fit inside of the tube  136 . For each slip hinge  124  of the plurality of slip hinges  124 , the base  134  is fixedly coupled to the mounting frame  120  and the tube  136  is fixed coupled to the secondary door  112 . The secondary door  112  may then be hingedly coupled to the mounting frame  120  by lowering the plurality of tubes  136  onto the prongs  138  of the plurality of bases  134 . The use of the slip hinge  124  for the combination door unit  100  allows the secondary door  112  to be easily removed when the secondary door  112  is open because the secondary door  112  can be lifted up, but limits the removal of the secondary door  112  when the secondary door  112  is closed. 
     As illustrated in  FIG.  8   , a method of installing a combination door unit  100  into a threshold  102  of a house may comprise a first step  140  of placing the combination door unit  100  within the threshold opening  102 , a second step  142  of leveling the combination door unit, a third step  144  of removing the secondary door  112  from the combination door unit  100 , a fourth step  146  of driving the second plurality of fasteners  126  through the mounting frame  120 , through the door frame  108 , and into the house frame studs  106 , and a fifth step  148  of replacing the secondary door  112  on the combination door unit  100 . Some of these steps may be excluded while still successfully installing the combination door unit  100 . For example, another method of installing the combination door unit  100  may exclude the second step  142 , the third step  144 , and the fifth step  148 . In such a method, the combination door unit  100  is simply placed within the threshold opening  102  and the second plurality of fasteners  126  is then driven through the mounting frame  120 , through the door frame  108 , and into the house frame studs  106 . 
     The second step  142  of leveling the combination door unit  100  may comprise inserting a plurality of shims  150  (see  FIG.  2   ) between the plurality of house frame studs  106  and the combination door unit  100 . The third step  144  of removing the secondary door  112  from the combination door unit  100  may comprise lifting each tube  136  of the plurality of slip hinges  124  off of the corresponding base  134  of the plurality of slip hinges  124 . The fourth step  146  of driving the second plurality of fasteners  126  through the mounting frame  120  may comprise driving the second plurality of fasteners  126  through the mounting flanges  132  of the mounting frame  120 . The fourth step  146  may comprise driving a first portion  152  of the second plurality of fasteners  126  through the first jamb  118 , driving a second portion  154  of the second plurality of fasteners  126  through a second jamb  156  of the two jambs  114 , and driving a third portion  158  of the second plurality of fasteners  126  through the head  116  of the door frame  108  (see  FIG.  5   ). The fifth step  148  of replacing the secondary door  112  on the combination door unit  100  may comprise placing each tube  136  of the plurality of slip hinges  124  onto the corresponding base  134  of the plurality of slip hinges. 
     The combination door unit  100  may be configured to include a multi-point lock system  160 , as illustrated in  FIGS.  9 A- 11 D . Some embodiments of the multi-point lock system  160  have a central throw  162  and at least two hooks  164 , as shown in  FIG.  9 B . Corresponding cavities  166  may be milled into the mounting frame  120 , as shown in  FIG.  9 C . The cavities  166  are configured to receive the central throw  162  and the at least two hooks  164 . The central throw  162  and the at least two hooks  164  may all be operatively coupled to one key hole  168 . When the key hole  168  is turned to a locked position, as shown in  FIGS.  10 A- 10 D , the central throw  162  and the at least two hooks  164  all extend out of the secondary door  112  and into the cavities  166 , thus locking the secondary door  120 . When the key hole  168  is turned to an unlocked position, as shown in  FIG.  11 A- 11 D , the central throw  162  and the at least two hooks  164  all retract into the secondary door  112 . 
     It will be understood that implementations of a combination door unit are not limited to the specific assemblies, devices and components disclosed in this document, as virtually any assemblies, devices and components consistent with the intended operation of a combination door unit may be used. Accordingly, for example, although particular combination door units, and other assemblies, devices and components are disclosed, such may include any shape, size, style, type, model, version, class, measurement, concentration, material, weight, quantity, and/or the like consistent with the intended operation of combination door units. Implementations are not limited to uses of any specific assemblies, devices and components; provided that the assemblies, devices and components selected are consistent with the intended operation of a combination door unit. 
     Accordingly, the components defining any combination door unit implementations may be formed of any of many different types of materials or combinations thereof that can readily be formed into shaped objects provided that the components selected are consistent with the intended operation of a combination door unit implementation. For example, the components may be formed of: polymers such as thermoplastics (such as ABS, Fluoropolymers, Polyacetal, Polyamide; Polycarbonate, Polyethylene, Polysulfone, and/or the like), thermosets (such as Epoxy, Phenolic Resin, Polyimide, Polyurethane, Silicone, and/or the like), any combination thereof, and/or other like materials; glasses (such as quartz glass), carbon-fiber, aramid-fiber, any combination thereof, and/or other like materials; composites and/or other like materials; metals, such as zinc, magnesium, titanium, copper, lead, iron, steel, carbon steel, alloy steel, tool steel, stainless steel, brass, nickel, tin, antimony, pure aluminum, 1100 aluminum, aluminum alloy, any combination thereof, and/or other like materials; alloys, such as aluminum alloy, titanium alloy, magnesium alloy, copper alloy, any combination thereof, and/or other like materials; any other suitable material; and/or any combination of the foregoing thereof. In instances where a part, component, feature, or element is governed by a standard, rule, code, or other requirement, the part may be made in accordance with, and to comply under such standard, rule, code, or other requirement. 
     Various combination door units may be manufactured using conventional procedures as added to and improved upon through the procedures described here. Some components defining a combination door unit may be manufactured simultaneously and integrally joined with one another, while other components may be purchased pre-manufactured or manufactured separately and then assembled with the integral components. Various implementations may be manufactured using conventional procedures as added to and improved upon through the procedures described here. 
     Accordingly, manufacture of these components separately or simultaneously may involve extrusion, pultrusion, vacuum forming, injection molding, blow molding, resin transfer molding, casting, forging, cold rolling, milling, drilling, reaming, turning, grinding, stamping, cutting, bending, welding, soldering, hardening, riveting, punching, plating, and/or the like. If any of the components are manufactured separately, they may then be coupled with one another in any manner, such as with adhesive, a weld, a fastener (e.g. a bolt, a nut, a screw, a nail, a rivet, a pin, and/or the like), wiring, any combination thereof, and/or the like for example, depending on, among other considerations, the particular material forming the components. 
     It will be understood that methods for manufacturing or assembling combination door units are not limited to the specific order of steps as disclosed in this document. Any steps or sequence of steps of the assembly of a combination door unit indicated herein are given as examples of possible steps or sequence of steps and not as limitations, since various assembly processes and sequences of steps may be used to assemble combination door units. 
     The implementations of a combination door unit described are by way of example or explanation and not by way of limitation. Rather, any description relating to the foregoing is for the exemplary purposes of this disclosure, and implementations may also be used with similar results for a variety of other applications employing a combination door unit.