Patent Publication Number: US-8109053-B2

Title: Door frame assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation of pending U.S. application Ser. No. 11/143,291, filed Jun. 1, 2005, which is incorporated by reference as if disclosed herein in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
     The present invention generally relates to a door frame assembly. In particular, the present invention is directed to a door frame assembly that may be installed after the wall and door opening is finished. 
     (2) Description of the Related Art 
     Existing door frame assemblies, i.e., frames, doors, and hardware, are typically supplied separately in multiple shipments and assembled on site. The process often involves problems with coordination, quality alignment, and missing components. 
     In commercial applications, hollow metal frames generally must be supplied in advance of wall construction and must be installed prior to wall completion. If delivery of the hollow metal frames is delayed, the overall construction schedule will be impacted as the completion of the walls will be delayed too. 
     Known door frame assemblies that may be installed post-drywall typically include knock-down frames and therefore cannot be shipped with pre-hung doors. Other known door frame assemblies require finish work such as taping, sanding, and painting and or the attachment of trim after the assembly is installed. Existing door frame assemblies take as much as 1-2 hours to install. 
     BRIEF SUMMARY OF THE INVENTION 
     One aspect of the present invention is a door frame assembly for installation with existing studs and walls. The door frame assembly includes a hinge jamb having a bottom end and a top end. The hinge jamb further includes a door side base connected to a door contact flange, which is connected to a non-door side trim attachment track. The non-door side trim attachment track is adapted to be fastened to the existing studs. A hinge jamb trim piece includes a connector portion configured to be removably retained within the non-door side trim attachment track. The hinge jamb trim piece is adapted to at least partially cover the non-door side trim attachment track and any fasteners. A lock jamb includes a bottom end and a top end and further includes a door side base connected to a door contact flange, which is connected to a connection flange, the connection flange adapted to be fastened to the existing studs. A lock jamb trim piece is adapted to at least partially cover the connection flange and any fasteners. A frame head jamb includes a hinge jamb end and a lock jamb end. The hinge jamb end is joined with the top end of the hinge jamb and the lock jamb end is joined with the top end of the lock jamb. The frame head jamb further includes a door side base connected to a door contact flange, which is connected to a connection flange, the connection flange adapted to be fastened to the existing studs. A frame head jamb trim piece is adapted to at least partially cover the connection flange and any fasteners. 
     Another aspect of the invention is a door frame assembly for installation with existing studs and walls, which includes a hinge jamb adapted to be joined with the existing studs and overlay the existing walls. The hinge jamb has a bottom end and a top end and further includes a door side base connected to a door contact flange, which is connected to a non-door side trim attachment track. The non-door side trim attachment track includes one or more fastener holes and is adapted to be fastened to the existing studs. A hinge jamb trim piece is adapted to overlay the existing walls. The hinge jamb trim piece includes a connector portion configured to be removably retained within the non-door side trim attachment track. The hinge jamb trim piece is adapted to at least partially cover the non-door side trim attachment track, the one or more fastener holes, and any fasteners. A lock jamb is adapted to be joined with the existing studs and overlay the existing walls. The lock jamb includes a door side base connected to a door contact flange, which is connected to a connection flange. The connection flange includes one or more fastener holes and the connection flange is adapted to be fastened to the existing studs. A lock jamb trim piece is adapted to overlay the existing walls and to at least partially cover the connection flange, the one or more fastener holes, and any fasteners. A frame head jamb is adapted to be joined with the existing studs and overlay the existing walls. The frame head jamb includes a hinge jamb end and a lock jamb end. The hinge jamb end is joined with the top end of the hinge jamb and the lock jamb end is joined with the top end of the lock jamb. The frame head jamb further includes a door side base connected to a door contact flange, which is connected to a connection flange. The connection flange includes one or more fastener holes and is adapted to be fastened to the existing studs. A frame head jamb trim piece is adapted to overlay the existing walls and to at least partially cover the connection flange, the one or more fastener holes, and any fasteners. A trim attachment bracket is sized to fit within at least one of the lock jamb and the frame head jamb and configured to removably secure at least one of the lock jamb trim piece to the lock jamb and the frame head jamb trim piece to the frame head jamb. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of illustrating the invention, the drawings show a form of the invention that is presently preferred. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein: 
         FIG. 1  is a front view of a door frame assembly according to one embodiment of the present invention; 
         FIG. 2  is a partial cross-sectional view of a hinge jamb according to one embodiment of the present invention; 
         FIG. 3  is an exploded view of the hinge jamb illustrated in  FIG. 2 ; 
         FIG. 4  is a top view cross-sectional of a door frame assembly according to one embodiment of the present invention; 
         FIG. 5  is a partial cross-sectional view of a lock jamb or frame head jamb according to one embodiment of the present invention; 
         FIG. 6  is an exploded view of the lock jamb or frame head jamb illustrated in  FIG. 5 ; and 
         FIG. 7  is a partial elevation cross-sectional view of a door frame assembly according to one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings in which like reference numerals indicate like parts, and in particular to  FIGS. 1-4 , the present invention is a door frame assembly  20  that may be installed post-drywall or after a wall and door opening or doorway  22  has been finished. In one embodiment, door frame assembly  20  includes a hinge jamb  24  joined to a lock jamb  26  via a frame head jamb  28 , all of which are joined with existing studs  30 - 32  and an existing wall  33 . 
     Hinge jamb  24 , which is typically formed from a contiguous metal extrusion, includes a bottom end  34  and a top end  36 . As best illustrated in  FIGS. 2-4 , in one embodiment and starting at one edge of hinge jamb  24 , the hinge jamb has a contiguous door side base  38  including a wall contact portion  40  joined with an outer surface portion  42 , which is joined to an inner surface portion  44 . Wall contact portion  40  forms a portion of the outer perimeter of door frame assembly  20  on a door side  46  of wall  33 , which is the side of doorway  22  that houses a door  48  and hinges  50  of the doorway, and contacts an existing wall board or drywall  52 . Inner surface portion  44  includes a flat portion  54  and a raised portion  56 , both of which are positioned within doorway  22 . Hinges  50  are joined with flat portion  54 . Raised portion  56  forms a door contact flange  58 . Door  48  may be sealed against door contact flange  58  when the door is closed. Door contact flange  58  is connected with a non-door side trim attachment track  60 , which may include one or more fastener holes  62  through which fasteners such as screws  64  or nails are passed to join hinge jamb  22  to existing stud  30 . 
     A hinge jamb trim piece  66 , which is also typically formed from a contiguous metal extrusion, includes a connector portion  68  configured to be to removably retained in non-door side trim attachment track  60  via a snap-fit or similar arrangement and wrap around to overlay an existing wall board or drywall  69 , which is on a non-door side  70  of wall  33 . While retained within non-door side trim attachment track  60 , hinge jamb trim piece  66  covers the non-door side trim attachment track, including fastener holes  62 , and any fasteners such as screws  64 . Continuing outwardly toward non-door side  70 , hinge jamb trim piece  66  also includes a flat inner surface portion  72 , which is joined with an outer surface portion  74  and a wall contact portion  76 . Wall contact portion  76  forms the outer perimeter of door frame assembly  20  on non-door side  70  of wall  33 , which is the side of doorway  22  that does not house door  48  and hinges  50 , and contacts existing drywall  66 . 
     Now referring to  FIGS. 5-7 , door frame assembly  20  also includes lock jamb  26  and frame head jamb  28 . Lock jamb  26 , which is positioned opposite hinge jamb  24  in doorway  22 , is joined with existing stud  31  and overlays existing wall  33 . Lock jamb  26  includes a bottom end  78 , which is adjacent to a threshold or floor  79 , and a top end  80 . Frame head jamb  28  includes a hinge jamb end  82  and a lock jamb end  84  and is positioned between hinge jamb  24  and lock jamb  26 , with hinge jamb end  82  in contact with top end  36  of the hinge jamb and hinge jamb end  84  in contact with top end  80  of the lock jamb. 
     Lock jamb  26  and frame head jamb  28  are typically formed from identical contiguous metal extrusions. Accordingly, the following description of the extrusions forming jambs  26  and  28  is combined. Starting at the edge positioned on door side  46  of wall  33 , each of jambs  26  and  28  has a door side base  86  including a wall contact portion  88  joined with an outer surface portion  90 , which is joined with an inner surface portion  92 . Wall contact portion  88  forms a portion of the outer perimeter of door frame assembly  20  on a door side  46  of wall  33 , which is the side of doorway  22  that houses door  48 , hinges  50 , and a strike plate  94  for receiving a latchbolt or deadbolt  96  of the lock (not shown), and contacts existing drywall  52 . Inner surface portion  92  includes a flat portion  98  and a raised portion  100 , both of which are positioned within doorway  22 . Strike plate  94  is joined with flat portion  98 . Raised portion  100  forms a door contact flange  58 ′. Door  48  may be sealed against door contact flange  58 ′ when the door is closed. Door contact flange  58 ′ is connected with a connection flange  102 , which may include one or more fastener holes  62 ′ through which fasteners such as screws  64 ′ or nails are passed to join either of jamb  24  or  26  to respective existing stud  31  or  32 . 
     Both lock jamb trim piece  104  and frame head jamb trim piece  104 , which are typically formed from identical contiguous metal extrusions, include an overlap portion  106  configured to overlap connection flange  102  and be positioned adjacent door contact flange  58 ′. Overlap portion  106  covers connection flange  102 , including fastener holes  62 ′, and any fasteners such as screws  64 ′. Continuing outwardly toward non-door side  70 , lock jamb trim piece  104  also includes a flat inner surface portion  108 , which is joined with an outer surface portion  110  and a wall contact portion  112 . Lock jamb trim piece  104  wraps around to overlay drywall  69 , which is on non-door side  70  of wall  33 . 
     In one embodiment, a trim attachment bracket  114 , which is sized to fit within lock jamb  26  and frame head jamb  28 , removably secures a respective trim piece  104  to each jamb by acting as a vehicle for a fastener such as a screw  64 ′, which binds the trim piece to the jamb. The fastener is introduced to trim attachment bracket  114  and ultimately both jamb  26  or  28  and trim piece  104  via a mute hole  116  in door contact flange  58 ′. Mute hole  116  is typically plugged with a rubber mute  118  after the fastener is introduced to trim attachment bracket  114 . As one skilled in the art will appreciate, any other known method or device may be used to bind trim piece  104  to jamb  26  or  28 . 
     Door frame assembly  20  is typically installed as a turnkey unit with door  48  and hinges  50  attached to flat portion  54  of door side base  38 . To install, door side base  38 , including door  48 , is positioned in door opening or doorway  22  by sliding it into the opening from the door side, i.e., the side of the assembly the door will swing from. Door frame assembly  20  is typically shipped with a temporary spreader bar (not shown). The temporary spreader bar is generally not removed until door frame assembly  20  is plumb and square. 
     Next, hinge jamb  24  is plumbed and squared. Typically, top end  36  of hinge jamb  24  must be moved slightly in the direction of the hinge jamb due to the weight of door  48  pulling toward lock jamb  26 . Hinge jamb  24  is typically moved by adjusting a top plumb anchor (not shown) on lock jamb  26  and a lower plumb anchor (not shown) on hinge jamb  24  to plumb the hinge jamb. The plumb anchors are typically adjusted by turning adjustment screws via access holes. After hinge jamb  24  is plumb, a plurality of sheet metal attachment screws  64  are run through fastener holes  62  and into existing stud  30 , thereby attaching the hinge jamb with the existing stud. Because screws  64  are for additional structural stability only, it is not required that they be tightened enough so that hinge jamb  24  is in contact with existing stud  30 . To finalize installation of hinge jamb  24 , additional screws known as sill screws (not shown) are generally run through additional fastener holes  62  adjacent bottom end  34  of the hinge jamb and into existing stud  30 . Next, lock jamb  26  is checked for plumbness and squareness. If required, adjustments are made using the plumb anchors (not shown) and/or raising lock jamb  26 . Once lock jamb  26  is plumb, the lock jamb is secured to existing stud  30  by running sheet metal screws  64 ′ through fastener holes  62 ′ on connection flange  102  into the existing stud. In addition, sill screws (not shown) are also run through fastener holes  62 ′ adjacent bottom end  78  of lock jamb  26  and into existing stud  30 . After lock jamb  26  is installed, the other two plumb anchors (not shown) are checked to make sure they are tight against the studs. 
     Next, the temporary spreader bar (not shown) may be removed and a trim portion (not shown in unitary form) of door frame assembly  20 , which includes hinge jamb trim piece  66 , lock jamb trim piece  104 , and frame head jamb trim piece  104  may be installed. The trim portion is installed from the non-door side by allowing lock jamb trim piece  104  to slide to the lock jamb side until it stops. Then, hinge jamb trim piece  66  is positioned so that connector portion  68  snaps into and bottoms out in attachment track  60 . Next, self drilling sheet metal screws  64 ′ are run through mute holes  116  and into lock jamb trim piece  104  until the trim piece is pulled tightly against door side base  86 . Then, sill screws (not shown) are typically inserted through trim pieces  66  and  104  and into existing stud  30  adjacent bottom ends  34  and  78 , respectively. Finally, each mute hole  116  is plugged with a rubber mute  118 . 
     A door frame assembly according to the present invention offers advantages over prior art designs in that it may be shipped as a completed door and frame unit with all components assembled, including finish paint, and may be installed in 10 minutes or less. A door frame assembly according to the present invention is typically supplied with welded corners that meet all SDI and NAAMM architectural specifications, and will generally meet all industry standards for physical endurance and fire ratings. 
     A door frame assembly according to the present invention is easier to install than known systems because it is reversible and may be swapped out with a different assembly at any time allowing recovery from installation errors and accommodation to construction changes. A door frame assembly according to the present invention is easily installed as two total pieces wrapped together from opposite directions and connected together by concealed fasteners. In addition, a door frame assembly according to the present invention may be configured to accept all residential or commercial hardware products. 
     A door frame assembly according to the present invention offers security advantages over known assemblies. Because the mute holes through which the fasteners are accessed are positioned on a portion of the frame assembly that is covered by the door, the door frame assembly is protected from disassembly when the door is closed and locked. 
     Although the invention has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. Accordingly, other embodiments are within the scope of the following claims.