Patent Publication Number: US-11047164-B2

Title: Door assembly

Description:
This application claims the benefit of U.S. provisional application No. 62/466,584, filed Mar. 3, 2017, which is herein incorporated by reference. 
    
    
     FIELD OF TECHNOLOGY 
     The present disclosure relates generally to entryways for a building and, more particularly, to frame members and a door assembly for a residence. 
     BACKGROUND 
     Frame components, such as, jambs and mullions, for exterior door systems are exposed to environmental elements and extremes such as moisture, temperature, and sunlight, which can attack and break down the frame material. Protective coatings such as exterior grade paints are typically used not only to improve appearance but also to protect the underlying material, which is traditionally and typically wood. These frame components are also prone to wicking up moisture from their bottom ends. This type of moisture can lead to decay over time, which compromises the appearance and structural integrity of the frame. Alternates to a traditional wood frame include aluminum cladded wood frames, which can be expensive, vinyl cladded wood frames, which are not very resistant to impact damage, or all-plastic extruded frames, which are not very rigid and are also susceptible to deformation under heat. 
     While all-plastic frames are more resistant to environmental degradation and may decrease maintenance needs, conventional all-plastic frames often include reduced structural strength. Other frames have included stiffening components of laminated wood or metallic type extrusions in attempts to address structural integrity degradation, however, such stiffening components create other challenges, by way of example, interfering with hardware fasteners used to anchor frames and frame components. 
     Thus, there remains a need for a new and improved door assembly and frame members that are decay resistant while, at the same time, have the appearance and strength of a traditional wood frame door assembly. 
     SUMMARY 
     The present disclosure is directed in one embodiment to a door assembly. The door assembly includes at least one door panel and a door frame having a plurality of frame members including a header and at least a pair of side jambs. The frame member includes a core; and a two-piece top piece adjoining the core to form a structural member with the core and the top piece is a composite of cellulosic material and at least one other material. The door assembly may further include an adjacent panel. The adjacent panel may be, in one example, at least one side light panel. In other examples, the panel may be a passive panel. 
     The core may be formed of a non-metallic material and preferably, in one embodiment, the core is a wood. Also, the core may further include a lower portion formed of a decay resistant material. In one embodiment, the lower portion formed of a decay resistant material is a cellulosic-plastic composite. The cellulosic portion of the cellulosic-plastic composite preferably is wood fiber. Also, the plastic portion of the cellulosic-plastic composite preferably is a thermoplastic. In one embodiment, the thermoplastic is a polyethylene. 
     In one embodiment, a door assembly may be considered a door frame member including at least one door panel. The door frame may have a plurality of frame members including a header and at least a pair of side jambs. The one frame member may include a core and at least one top piece. The top piece may include one or more hollow cavities. The top piece may adjoin to the core to form a structural member with the core. The door frame assembly may also include a trim profile. 
     The top piece may be a two-piece top piece and includes a stop portion and a rabbet portion. In one embodiment, the stop portion and the rabbet portion are generally L-shaped and the proximate end of the stop portion overlaps the corresponding proximate end of the rabbet portion. The overlapping proximate ends of the rabbet portion and the stop portion may form a weather strip slot and may further include a weather strip adapted to be received by the weather strip slot. In addition, the stop portion and the rabbet portion may be generally L-shaped and the distal ends of the stop portion and the rabbet portion may each or all overlap the sides of the underlying core. The top piece may include hollow cavities. 
     In other embodiments, the top piece may be a linear piece, the rabbet portion may be a linear piece, and/or may take on other configurations. 
     In one embodiment, the two-piece top piece is formed of a decay resistant material. The two-piece top piece may be a cellulosic-plastic composite. Preferably, the cellulosic portion of said cellulosic-plastic composite is wood fiber. The plastic portion of the cellulosic-plastic composite preferably is a thermoplastic. In one embodiment, the plastic is a polyvinyl chloride. 
     The amount of cellulosic material in the cellulosic-plastic composite may be between about 20 wt. % and about 70 wt. % of the weight of the cellulosic-plastic composite. Preferably, in one embodiment, the amount of cellulosic material in the cellulosic-plastic composite is between about 25 wt. % and about 45 wt. % of the weight of the cellulosic-plastic composite. In another embodiment, the amount of cellulosic material in the cellulosic-plastic composite is about 35 wt. % of the weight of the cellulosic-plastic composite. 
     The thickness of the two-piece top piece may be between about 10% and about 50% of the thickness of the frame member. In other embodiments, the thickness of the two-piece top piece is between about 10% and about 50% of the thickness of the frame member. In one embodiment, the thickness of the two-piece top piece is about 30% of the thickness of the frame member. 
     The frame member may further include a binder between the core and the two-piece top piece for attaching the core to the two-piece top piece to form the frame member. Preferably, in some examples, the binder is an adhesive. In one embodiment, the adhesive is a hot melt adhesive. 
     In one embodiment of the door assembly, each adjacent panel adjoins a mullion extending between the header and the base of the door assembly. Also, the door assembly may further include a sill extending underneath the at least one door panel. Further, the at least one door panel may be a raised panel door. In one embodiment, the door panel further includes at least one window panel. 
     The door assembly may further include hinges located between the door panel and the door frame or a mullion. Also, the door assembly may further include locking hardware to secure the at least one door panel to the door frame. 
     A frame member may be a door jamb and/or a door mullion, in various examples. 
     Accordingly, one aspect of the present disclosure is to provide a door assembly, the door assembly including at least one door panel and a door frame having a plurality of frame members including a header and at least a pair of side jambs; wherein the frame member includes a core and at least one top piece adjoining the core to form a structural member with the core and wherein the top piece is a composite of cellulosic material and at least one other material. 
     Another aspect of the present disclosure is to provide in a door assembly, including a door frame having a plurality of frame members, including a header and at least a pair of side jambs, the frame member including a core and a two-piece top piece adjoining the core to form a structural member with the core. The top piece, in this embodiment may be a composite of cellulosic material and at least one other material. 
     Still another aspect of the present disclosure is to provide a door assembly, the door assembly including at least one door panel and a door frame having a plurality of frame members including a header and at least a pair of side jambs. The frame member may include a core and a two-piece top piece adjoining the core to form a structural member with the core and the top piece is a composite of cellulosic material and at least one other material; and at least one side panel. The side panel, by way of example may be a light panel and/or a fixed panel. 
     Still in other embodiments, the present disclosure may be considered a frame member including a core and a two-piece top piece adjoining the core to form a structural member with the core and the top piece being a composite of cellulosic material and at least one other material. The top piece may be a 2-piece top piece and include a top piece cover and a top piece base. 
     The top piece cover may be a removable cover and fit removably with a top piece base. A hollow cavity may be formed between the top piece base and the top piece cover. A level assembly may be incorporated into a hollow portion of the top piece. The level assembly may be encased within the hollow cavity between the top piece base and the top piece cover. The level assembly may only be viewable externally when the top piece cover is removed. The level may provide installation feedback to assist in assembly and installation of frame members and door assemblies. 
     Examples may also include a door frame member for a door frame assembly including a hybrid jamb member. The hybrid jamb member may include a core and a top piece. The top piece may be formed of a rigid extrusion of a cellulosic-plastic composite material. The top piece may align with the core along the length of the core. There may be at least one hollow portion formed in the top piece between a top of the top piece and a base of the top piece. The hybrid jamb member may also include a trim profile. A length of the trim profile may be perpendicularly fitted to the length of the core and a length of the top piece. The top piece cover may include a downwardly projecting outer leg, a midleg, and an inner leg. The top piece base may include an upwardly projecting outer leg, a mid leg, and an inner leg. The outer leg of the cover may mate with the outer leg of the base and the mid leg of the cover. The mid leg of the base and of the cover may be configured to contact each other in a biased position, securing the cover to the base. 
     In other examples, a door assembly may include a door frame member including a core, a top piece and a vertically oriented trim profile/brick mould. The top piece may adjoin the core to form a structural member with the core. The top piece may include a stop portion and a rabbet portion adjoining to form a slot. The vertically oriented trim profile may mate with the core and the top piece. The trim profile may include at least one hollow cavity. 
     The frame members may be jambs. The frame members may be mullions. 
     These and other aspects of the inventions of the present disclosure will become apparent to those skilled in the art after a reading of the following description of embodiments when considered with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front elevation view of one embodiment of a door assembly constructed according to the present disclosure; 
         FIG. 2  is cross-sectional view of one embodiment of a frame member having a core, a trim profile and a top piece; 
         FIG. 2A  is an alternative cross-sectional view of one embodiment of the frame member of  FIG. 2 ; 
         FIG. 3  is another cross-sectional view of one embodiment of a frame member having a core, a trim profile and a top piece; 
         FIG. 3A-3B  show another cross-sectional view of embodiments of a frame member having a core, trim profile and a top piece; 
         FIG. 4  is another cross-sectional view of one embodiment of a frame member having a core, a trim profile and a top piece; 
         FIG. 4A  is a cross-sectional view of one example of the frame member of  FIG. 4  with a portion of the top piece removed; 
         FIG. 4B  is a perspective view of one embodiment of a frame member having a level assembly; 
         FIG. 4C  is a cross-sectional view of one embodiment of the frame member of  FIG. 4B  having a level assembly; 
         FIGS. 4D-F  show various views of the level assembly of  FIG. 4B ; 
         FIGS. 5A-5C  shows one embodiment of an outer leg configuration of one example of a top piece according to the present disclosure; 
         FIG. 5D  is a perspective view of one embodiment of a frame member including a pull according to the present disclosure; 
         FIG. 6  is one example of a trim profile constructed according to the present disclosure; 
         FIG. 7  is another example of a trim profile constructed according to the present disclosure; 
         FIG. 8  is another example of a trim profile constructed according to the present disclosure; 
         FIGS. 8A and 8B  show alternate examples of the trim profile of  FIG. 8 ; 
         FIG. 9  is another example of a trim profile including a trim profile cover constructed according to the present disclosure; 
         FIGS. 9A-D  show alternate examples of the trim profile including a cover according to  FIG. 9 ; 
         FIG. 10  is a side perspective view of one example of a frame member having a lower portion; 
         FIG. 11  is a graphical representation of a response surface illustrating the relationship of the thickness of the top piece and the amount of cellulosic material in the cellulose-plastic composite on the performance of a frame member constructed according to some examples of the present disclosure; 
         FIG. 12  is a front elevation view of one embodiment of a door assembly constructed according to the present disclosure; 
         FIG. 13  is a front elevation view of another embodiment of a door assembly constructed according to the present disclosure; 
         FIG. 14  is a front elevation view of another embodiment of a door assembly including at least one mullion frame member and constructed according to the present disclosure; 
         FIG. 15  is a cross-sectional view of one embodiment of a mullion frame member having a reinforced core and a top piece; and 
         FIGS. 16A-16C  are alternative examples of cross-sectional views of embodiments of a mullion frame member having a reinforced core and a top piece. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such tetras as “forward,” “rearward,” “left,” “right,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting tetras. 
     Referring now to the drawings in general and  FIG. 1  in particular, it will be understood that the illustrations are for the purpose of describing a preferred embodiment of the inventions and are not intended to limit the inventions thereto. As best seen in  FIG. 1 , a door assembly, generally designated  8 , is shown constructed according to the present disclosure. The door assembly  8  includes a door frame  10  and at least one door panel  12 . 
     The door frame  10  may include one or more frame members  29  (see  FIG. 2 ). A plurality of frame members may include any combination of a header  14  and a pair of side jambs  16 ′ and  16 ″. Header  14  may be generally placed toward the top of the door panel  12 . Side jambs  16 ′ and  16 ″ may be generally placed at opposing sides of the door panel  12 . However, in some embodiments, the side jambs are not directly adjacent to the door panel  12 . Door panel  12  may further include hinges  20 . Hinges  20  may connect door panel  12  to at least one of the frame members. In another embodiment, hinges  20  may connect door panel  12  to a mullion. There may be one, two, three or more hinges  20 . 
     In other embodiments, the door panel  12  may also include locking hardware that enables the door panel to be secured to at least one of the frame members; for example, side jamb  16 ″. Some examples of locking hardware include latches and deadbolts. Alternatively, door panel  12  may include locking hardware that enables it to be secured to a second door panel. Still in other embodiments, door panel  12  may include locking hardware to secure it to a mullion. More than one type of locking hardware mechanism may be used in certain embodiments; for instance, wherein at least two door panels may be used to constitute a French door assembly. In another embodiment, the door panel  12  is a raised panel door. The door panel  12 , in one example, may include adjacent panels, for example, side light panels  42 ′ and  42 ″ and in other examples may include side light panels (see  FIGS. 12 and 14 ). The door panel  12  may also include raised panels and/or glass panels, for example,  24 ′ and  24 ″. 
     Turning to  FIGS. 2-3 , and in some examples, the frame member  29  may include a core  26  and a top piece  30 , as seen in  FIGS. 2 through 4 , and generally throughout the figures. The top piece  30  may include a binder (not shown) that attaches it to the core  26 . The binder may be an adhesive. In one embodiment, the binder may be an adhesive such as a hot melt adhesive. Core  26  may be of a material that provides additional structural stability while top piece  30  can be included, for example, for structural stability and/or aesthetic features. Core  26 , may, by way of example, be of wood, part wood, and/or all or part wood/plastic composite, laminated veneer lumber, and/or wood and another material. Top piece  30  may also serve other functions such as protecting the core  26 . The core  26  may further include back out grooves  27  (not shown) on a face that is not attached to the top piece  30 . 
     In one embodiment, the top piece  30  may be comprised of one piece. In another embodiment, top piece  30  may be comprised of two joined pieces, a first piece and a second piece, and/or may be comprised of two or more joined, connecting and/or non-joined pieces. Other embodiments of top piece  30  may include additional pieces and/or separate pieces. Still in other embodiments, top piece  30  is a single piece. As shown in the embodiment in  FIG. 2 , the two piece top piece  30  is, in this embodiment, comprised of a rabbet portion  32  and a separate stop portion  34 . In one embodiment, the two top pieces are generally L-shaped. The top piece may be linear and other shapes may alternatively be used. 
     The core  26  may be of any shape with any defined length (“CL”), width (“CW”) and depth (“CD”). The two-piece top members are flexible dimensionally in design and can accommodate any span of core sizes, including multiple cores. In one embodiment the core width is about 5¼ inches. In another embodiment the core width is about 7¼ inches. In another embodiment, the core width may be from about 4″ to about 8″. Either the rabbet portion  32 , the stop portion  34  or both can be adjusted in their respective widths (“RW” and “SW”) to accommodate the core&#39;s width to maintain the overlap at the proximate ends  31 ,  33 . In a number of embodiments, the rabbet portion  32  is at a fixed standard width while the stop portion  34  can be accommodating and manufactured at a variety of widths. Still, the rabbet portion  32  may also be manufactured at a variety of widths to accommodate the needs of the installation/application. 
     In some embodiments, the core  26  may include a partially raised portion  23  to support at least one of the top pieces. Raised portion  23  may be a portion of the core that is raised, non-linear, in a different plane and parallel to the main core portion. This portion  23  may be integrally formed with the main core from one core material. Alternatively, this portion  23  may be adjoined from separate components to wholly form the core  26 . In the embodiment shown in  FIG. 2A , the core  26  has a first portion  21  (having a length (“CL 1 ”), width (“CW 1 ”) and depth (“CD 1 ”)) to support the rabbet portion  32 . The core may also include a second raised portion  23  (having a length (“CL 2 ”), width (“CW 2 ”) and depth (“CD 2 ”)) to support the stop portion  34 . The first and second portions of the core  26  may be of any length, width and depth. The second raised portion  23  of the core  26  may enable the stop portion  34  to at least partially overlap the rabbet portion  32 . In yet other embodiments, the first and second portions of the core are attached to a single top piece molded to fit both portions of the core  26 . 
       FIGS. 2 through 4  show that the top piece may include an overlap and form a slot  36 . The slot  36  may be a weather strip slot that further includes a weather strip  40 . Weather strips are useful for preventing water and air from entering the interior of a building. The slot  36  may accept the weather strip between the proximate ends  31  and  33 . 
     In some embodiments, where the stop portion  34  extends over the rabbet portion  32  to form an overlap, the rabbet portion  32  and stop portion  34  of the top piece  30  embodiments may overlap in any number of configurations. In one embodiment, the proximate end  33  of the stop portion  34  overlaps with a corresponding proximate end  31  of the rabbet portion  32 . In some examples, the proximate end  33  of stop portion  34  meets the proximate end  31  of rabbet portion  32  by about an overlap of about 0″ to about ½″. 
     Still in other embodiments, the overlap may be substantially medially located over the core. The location of the overlap with respect to the core  26  may depend on the dimensions of its portions, particularly CW 1  and CW 2 . In some embodiments, CW 1  and CW 2  may be of widths such that the overlap is closer to a distal end  35  of the rabbet portion  32  than a distal end  37  of the stop portion  34 . In other embodiments, the overlap is closer to the distal end  37  of the stop portion  34  than distal end  35 . 
     The extent of overlap may also depend on the depths and widths of the rabbet and stop portions of the top piece. In one embodiment, the stop portion  34  has a greater width (“SW”) than the width of the rabbet portion  32  (“RW”). In another embodiment, the proximate end  33  of stop portion  34  has a greater depth (“SPD”) than the proximate end  31  of the rabbet portion  32  (“RPD”). 
     The top piece/pieces may also sit on top of the core  26  in a variety of configurations. As shown in  FIG. 2 , the distal ends  35 ,  37  of the rabbet portion  32  and stop portion  34  both overlap the sides of the underlying core  26 . In one embodiment, the depth of the core (“CD 1 /CD 2 ”), at least at the core&#39;s greatest depth, is greater than the depths of the distal ends  35 ,  37  of the rabbet portion  32  (“RDD”) and stop portion  34  (“SDD”). In other embodiments, the depths of the distal ends  35  and  36  are equal to or greater than the depth of core  26 . Furthermore, the depth of distal end  37  may be greater than distal end  35 . 
     In other embodiments, the core  26  is non-metallic. By way of example, the non-metallic material may be wood. The core  26  may also further include a decay resistant material. Decay resistant materials are useful for extending the lifespan of the core, such as through preventing water damage. In one embodiment, the decay resistant material may be a cellulosic-plastic composite. The cellulosic portion of the composite may be wood fiber. The plastic portion of the composite can be a thermoplastic such as polyethylene. In other embodiments, the entire core may include a decay resistant material. The core may include a first portion made of a first material and a second portion made of a second material. The first material may be a material different from the second material. 
     As seen in  FIG. 10 , the decay resistant material may be generally located on a lower portion  28  of the core. The lower portion  28  of the core may generally refer to a portion that is closer to the ground. The lower portion  28  may be an integrally formed segment as depicted in  FIG. 10 . This segment can be an extruded profile that matches the profile of the wood core. In the embodiment shown in  FIG. 10 , the integral segment is joined to the core  26  by a finger joint. However, the decay resistant material may be joined to the core  26  by any mechanical or chemical means and is not limited to connecting via a particular type of joint. Further, the integrally formed segment may be of any length with respect to the core. By way of example, the length of the segment may be about 4″. In some examples, the lower portion  28  may be formed of foamed PVC. 
     The top piece  30  may also be a decay resistant material. This decay resistant material may be a cellulosic-plastic composite. In one embodiment, the cellulosic portion of this composite is a wood fiber. In another embodiment, the plastic portion of the composite is a thermoplastic such as polyvinyl chloride. In some examples, the top piece may be a resin and filler combination material. 
     The amount of cellulosic material may vary within the top piece composite. In one embodiment, the top piece composite is between about 20 weight percent and about 70 weight percent of the weight of the cellulosic-plastic composite. In another embodiment, the amount of cellulosic material within the composite is about 35 weight percent of the total weight of the cellulosic-plastic composite. The thickness of the top piece  30  may also vary among different embodiments of the invention. In one example, the thickness of the top piece  30  is between about 10% and about 50% of the thickness of the total frame member, including the core. In one embodiment, the thickness of the top piece  30  is about 30% of the thickness of the door frame member  29 . 
       FIG. 11  is a graphical representation of a response surface illustrating the relationship between the percent thickness of the top piece and the amount of cellulosic material in embodiments where the top piece is a cellulosic-plastic composite. Percent thickness of the top piece is defined as the thickness of the top piece with respect to the total thickness of the frame member. The response surface provides a visual illustration of the effects of both thickness and percent amount of cellulosic material within the composite via a two-dimensional surface plot of a three-dimensional surface. The boundary conditions in  FIG. 11  are denoted with dashed lines, and indicate a minimum percent thickness and a percent amount of cellulosic material for use with some examples within the present disclosure. 
     Accordingly, in this example, the expected characteristics of various embodiments of top piece  30  were plotted and zones on the response surface were ranked from 1 to 5, with 1 being the poorest performing top pieces and 5 being the best performing top pieces in terms of strength, durability and resistance to decay. 
       FIGS. 3-4  show top piece  30  may include at least one hollow cavity  38 . More than one hollow cavity may be separated by a support rib  39 . Top piece  30  may include both a horizontal hollow cavity  38   a  spanning longitudinally along the length of the top piece and a vertical hollow cavity  38   b  spanning along the depth of the top piece. Cavity  38  may allow for placement of items such as installation anchors and/or level indicators  49 . Hollow cavity  38  inclusion in top piece  30  may allow for more consistent extrusion of top piece  30 . The hollow cavities  38  may span the entire width of the top piece  30 . The frame member may include a series of hollow cavities included in top piece  30 . 
     In some embodiments, as seen specifically in  FIGS. 3A and 3B , the top piece  30  may include a seal  97 . The seal  97  may be a projection into recess  99 . The seal  97  may be a flexible seal. The seal  97  may be co-extruded with top piece  30 . The seal  97  may form a battier to entry of water and weathering at the juncture between the top piece  30 , other part/s of the frame member  29  and the flange  77 . 
     Top piece  30  may also, in some embodiments, include a top piece cover  41 . The top piece may also include a top piece base  55  (see  FIGS. 4-5C ). The top piece base may include, by way of example, a part of the rabbet portion  32  that houses, is covered by and/or interfaces with the top piece cover  41 . The top piece cover  41  may interface with top piece base  55  and rabbet portion  32  to form the complete top piece, however, in some examples the rabbet portion and stop portion  34  formed by interface of the cover  41  may be separate pieces.  FIGS. 5A-C  show examples of a top piece base  55  interfacing with top piece cover  41 . In one example, an outer leg  43  of the cover  41  hooks/mates with the outer leg  53  of base  55 . The outer leg of the cover  41  may include a lip  44 A. The outer leg  53  of base  55  may include a lip  44 B. The outer leg lip  44 A and the top piece lip  44 B may overlap to secure the cover  41  to the base  55 . A mid leg  45 A of the cover may contact with a mid leg  45 B of the base. The interaction of the mid leg of the cover  45 A and the mid leg  45 B of the base may cause the cover to bias in one direction, away from the interface of the outer leg lip  44 B and the cover lip  44 A, further securing the interface between the outer leg lip and the cover lip. The cover  41  and the base  55  may also both include an inner leg  46 ,  47 . Each of the inner legs may include an inner leg lip  48 A,  48 B. The inner leg lip  48 A of the cover  41  may snap and/or slide onto the inner leg lip  48 B of the base  55 , securing the cover  41  in place on the base  55 . The top piece in this example may be considered a top piece assembly including a core  26  and a top piece  30 , with the top piece including a rabbet  32  and a stop  34 . The stop  34  may include a base  55  and a cover  41 . The cover  41  may secure onto the base  55  such that the cover and the base form the stop face. The cover  41  and the base  55  may form at least one or more hollow cavity  38 . 
     A level assembly  49  may be situated in the hollow cavity  38  between the top piece base  55  and the top piece cover  41 . The hollow cavity can be formed by removing ribs  39  as needed, by machining  FIGS. 4B-4D  show examples of a level assembly incorporated in a frame member. The level assembly may be of a height and of dimensions to be accommodated within the hollow cavity  38 . The top piece cover  41  and the top piece base  55  may enclose the level assembly  49 . The level assembly may include a body  90 , fittings  98  along the perimeter of the body  90 , a level site  94 , a bubble level  96  and indicators  92 . 
     One example of a door assembly may include a pull  91  fitted between a removable top piece cover  41  and a top piece base  55  to assist with removal of the top piece cover  41  from the top piece base  55  (as seen in  FIG. 5D ). The pull  91  may be made of a durable material, by way of example, the pull may be a mylar pull. The door assembly may include multiple pulls. A pull  91  may be configured across a width of the top piece cover. A pull  90  may be attached to an underside of a cover  41 , in one example, by an adhesive  93 . The pull  90  may span from one underside edge of the cover to another underside edge of the cover and extend outside of the cover between the cover and the base to be exposed on the outside of the door frame member. The pull is thin enough to not impede the closure of the cover  41  onto the base  55 , and may be fitted between a mid leg of the cover  45 A and a mid leg of the base  45 B without interrupting the biasing position exerted by the placement of the mid legs  45 A,  45 B. The pull is also strong enough to withstand repeated removal of the cover by way of tension on the pull  91 . 
     Frame member  29  may also include, in some examples, trim profile  70 , as seen in  FIGS. 2 through 4 . Trim profile  70  may be incorporated as a part of the frame member in any of a variety of ways and may take on a variety of shapes. Trim profile  70  may be a one piece trim profile. Trim profile  70  may include multiple portions, segments, and/or attachments. Trim profile  70  may take on a vertical orientation and be adjustable relative to the jamb portion of the frame member  29 . 
       FIGS. 6 through 9  show enlarged views of examples of a trim profile  70 , by way of example, a brick mould. In one embodiment, trim profile  70  may include a linear side  71  that abuts the top piece  30  and/or core  26  and/or a portion of the top piece  30 . Trim profile  70  may also include a non-linear side  72 . Trim profile  70  may include a first portion  75  and a second portion  76 . 
     First portion  75  may take on an enclosed square or rectangular shape. First portion  75  may have two linear sides that are parallel with each other and with distal end  37 . First portion  75  may include one or more hollow portions  73 . First portion  75  may be an enclosed portion. First portion  75  may be separated from second portion  76  by a support rib  39 . First portion  75  may also include a stop flange  77 . Stop flange  77  may be joined to linear side  71  substantially perpendicularly, forming about a ninety degree angle between the flange  77  and side  71 . Flange  77  may fit in a recess  99  formed between an underside of the stop  34  and the core  26 . The flange  77  may clearance fit with recess  99 . The trim profile  70 , in one example, may overlap with the stop  34  of top piece  30 . The frame member  29  may include reciprocal recesses at both terminal ends of the stop portion  34 , by way of example at the distal end  37  and at the proximate end/stop face end  33 . 
     Second portion  76  may include a linear side and a non-linear side. Second portion may include one or more hollow portions  74 . Second portion  76  may be enclosed and/or may take on a non-enclosed shape. Second portion  76  may include a flange  78  extending from linear side  71  and projecting beyond portion  76 . Second portion  76  may include a projecting segment  78  that forms the termination of linear side  71  on one end. A projecting segment  79  may extend from non-linear side  72  and be separated from the linear side  71  by a hollow cavity/portion  74 . Cavity  74  may be formed by projecting segment  79  and may be configured for the cavity of a corner key (not shown) to connect horizontal and vertical pieces at a miter joint. 
     The trim profile  70  may be at least a two piece trim profile. Trim profile  70  may include a base segment  82  and a cover segment  80 . Base segment  82  may form the linear side  71  and may include a flange  77  and/or a recess  83 . Cover  80  may adjoin base segment  82 . Cover  80  may include a lip  84  that fits into recess  83  to secure cover  80  to base segment  82 . Trim profile  70 , in this example, may include a horizontally oriented hollow portion  74  and/or a vertically oriented hollow portion  74  and a series of hollow portions  73 . Support ribs  39  and hollow portions  73 / 74  may take on varying configurations, by way of example 6-9D. In one example, support ribs  39  may take on vertical, linear, and/or combinations of orientations to faun segmented hollow portions  73 / 74  in configurations that assist in structure and the extruding process. Applicant realizes benefits in material minimization and cost efficiency, particularly in the top piece  30  and the trim profile  70 . The material minimization is balanced against shape control and stability factors. The support ribs  39  may be minimized for material minimization and also intentionally configured and shaped to provide adequate or improved structure to the top piece  30  and trim profile  70 . 
     In other embodiments, trim profile  70  may include an insert  81 . Insert  81  may, by way of example, be wood or other suitable material to provide an anchor point for fasteners, for example storm door fasteners. 
       FIGS. 8A and 8B  show that a portion of the trim profile between projecting segments  79  and  78 , shown present in  FIG. 8A  and removed in  FIG. 8B , may be cut away. The removable segment between projecting segments  78  and  79  may be cut away to allow, for example, vinyl siding J-Channel fitment. 
     Frame members  29  may be a part of any type of door assembly. For instance, the door assembly  8  may include at least one adjacent panel, designated as  42 ′ and  42 ″ in  FIGS. 12 and 14 , such as a side lite panel or a fixed panel. In certain embodiments, frame members may also include a mullion  44 ′ and  44 ″. Each adjacent panel may also adjoin a mullion  44 ′ and  44 ″ extending between the header and base of the door assembly  8 . The door assembly  8  may further include a sill  46  located underneath the door panel. In other embodiments, as shown in  FIG. 13 , the door assembly includes two door panels  12 ′ and  12 ″ separated by way of example an astragal and/or a mullion  50 . In yet other embodiments, the frame members described herein are not necessarily limited to door jambs and mullions and may alternatively be used for other assemblies such as windows. 
     Some examples include an adjustable frame member  29 . An extended length core  26  and an extended length flange  77  may be included in an adjustable width frame system. The system may include the extended length core  26  and extended length flange  77  that are configured to be cut down or adjusted as needed to create a custom fit and narrower door jamb upon installation. Jambs are typically plumb and often fit against surfaces that may not be plumb. In one example, the adjustable width frame system may be a 2-piece system, including an extended length core  26  and/or an extended length flange  77 , the system configured to also allow a give and positionablility within the adjustable frame member  29  to adjust to non-plumb surfaces at installation. Therefore, the adjustable width frame system is configured to accommodate variable door jamb sizing requirements and also non-plumb installation surfaces. The core  26  may extend beyond the top piece  30  in an adjustable width frame system. The system may include any of the jamb embodiments disclosed herein with an extended length core  26  and/or an extended length flange, by way of example, specifically the jamb frame member shown in  FIG. 3 ,  FIG. 3A  and  FIG. 3B . 
     Frame members may also include one or more cappings (not shown). One alternative embodiment includes wherein the rabbet portion  32  and stop portion  34  each further includes a capping. Capping may be co-extruded with the top piece  30 , and is not necessarily limited to one layer. Alternatively, capping may be independently extruded to fit on top of a frame member and may cover at least a portion of a frame member. In one embodiment, the capping is a thermoplastic such as acrylic. In another embodiment, capping may be a composite of two or more materials. The composite of the capping may be comprised of a thermoplastic with a cellulosic filler such as wood. In other embodiments, the capping can be made of plastic without cellulosic filler, with another type of filler, or include a blowing agent. In other embodiments a capping may be placed onto core  26  without top piece  30 . A capping may comprise two or more pieces, but in other embodiments, may comprise one piece covering at least a portion of core  26 . 
       FIGS. 15 and 16A -C show embodiments where at least one frame member is a mullion having a core and a top piece. The top piece may be a 2-piece top piece. The mullion frame member may be structured similarly, as described herein throughout, as a jamb frame member, for example, of  FIGS. 2-9 . 
       FIGS. 15 and 16  show another example of embodiments of a frame member  29  including a mullion component according to the present disclosure. The mullion component may be made of a durable material, resistant to degrading effects of moisture, heat and fungal attack. The mullion component may include an extruded aluminum reinforced core. In some examples, the mullion frame member  29  includes a stop component and a rabbet component, each formed by extruding a combination of PVC, wood fibers and a foaming agent. The components may be joined to an aluminum reinforced core by an adhesive. The aluminum extrusion is able to mate with slots integrally formed in the composite extrusions for proper positioning. The reinforced core and top piece are positioned to maximize contribution to structural and shaping integrity, to eliminate issues related to thermal transfer and interior moisture condensation, to accommodate placement of hardware fasteners without the need to pre-drill through the reinforced core, and to maximize hardware fastener holding strength. 
     In some examples, the invention of the disclosure may be considered an exterior door mullion including extrusions joined to a reinforced core member  26 . In some examples, the extrusions may be a rabbet extrusion  32  and a stop extrusion  34  made of a moisture and decay resistant material, by way of example, all-plastic, a resin and plastic combination with wood or another suitable filler, and/or a blowing agent. The reinforced core member  26  may be a rigid member made of a rigid material, by way of example, aluminum. The reinforced core member  26  may be secured to the extrusions  32 ,  34 , in one example, by way of adhesive. The reinforced core member and multiple extrusions may be configured to form a slot  36 , the slot being configured to accept a weather stripping piece  40 . 
     In other examples, the frame member  29  may be considered a mullion component including a one piece stop portion  34 , a one piece rabbet portion  32  and a reinforced core  26 . The stop portion may include a stop face  33 , a recessed area  86  at the stop face, and a set of recessions  88 . The rabbet portion  32  may include a recessed area  87 . The reinforced core may take on the shape of at least a double-pronged fork and be sized and shaped to correspond to the recesses  88 ,  87  in the stop portion  34  and rabbet portion  32 . The reinforced core may on the pronged side mate with the stop portion  34 , with the prongs fitting into the recessions  88 . The reinforced core on an opposite side, may mate with the rabbet portion  32  and extend into the recessed area  87 . The reinforced core  26  may span the depth of the rabbet portion  32 . The recessed area  86  may be configured to form a slot  36  when the rabbet portion and stop portions are joined. The stop portion and rabbet portion may be separated by the reinforced core except along an inner interface adjacent to the slot  36 . Shapes and sizes of the mullion components may vary as seen in the examples of  FIG. 16A-C  to accommodate various door assemblies, and are considered within the scope of this invention. 
     Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example, the top piece can be of a unitary construction. The thickness of the top piece can be less than 10% of the total thickness in other embodiments. The plastic portion of the top piece may comprise all polyvinyl chloride. Moreover, the top piece can be made of plastic without cellulosic filler, with another type of filler, or include a blowing agent. Alternatively, the core&#39;s lower portion may be made from plastic without cellulosic filler, with another type of filler, or include a blowing agent. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims