Patent Publication Number: US-2018044970-A1

Title: Door frame

Description:
RELATED APPLICATION 
     The present application claims priority to GB Application No. 1613966.9, filed 15 Aug. 2016. The above-referenced application is hereby incorporated by reference into the present application in its entirety. 
     FIELD 
     The present disclosure relates to door sets for use in healthcare applications. In particular, it relates to a door frame where an anti-barricade function is required, for example in a psychiatric ward. 
     BACKGROUND 
     To ensure the safety of both patients and staff in healthcare environments, for example psychiatric wards, doorways need to provide a number of different functions. For example, a door set, which is comprised of a door leaf and a frame, should be able to resist lateral loads from patients trying to force their way in or out of the door. The doors should also allow two-way opening in the instance that opening in one direction is prevented by a patient barricading themselves in. The doors should have a single leaf in order to provide as simple a structure as possible. The door should also have anti-ligature functionality to reduce, or prevent entirely, the possibility of a patient causing themselves harm by using part of the door set. Each of these criteria should be met whilst also providing a door set that is capable of installation in a number of differently configured door spaces. 
     SUMMARY 
     In accordance with an aspect of the disclosure there is provided a door frame assembly, comprising a first frame member comprising a first door frame casing for one side of a doorway and jambs projecting therefrom, a second frame member comprising a second door frame casing for another side of the doorway and jambs projecting therefrom, wherein the two frame members are arranged to fit together in a plurality of overlapping positions to form the door frame assembly such that the jambs of the first frame member overlap the jambs of the second frame member by different respective amounts in each of the plurality of overlapping positions to allow the door frame assembly to be applied to walls of different thicknesses. 
     Optionally, the jambs projecting from the first door frame casing comprise a first jamb element, a second jamb element and a first head jamb element between the first jamb element and the second jamb element, the jambs projecting from the second door frame casing comprise one or more third jamb elements, one or more fourth jamb elements and one or more second head jamb elements between the one or more third jamb elements and the one or more fourth jamb elements, and in each of the plurality of overlapping positions, at least a portion of the first jamb element overlaps at least a portion of the one or more third jamb elements, at least a portion of the second jamb element overlaps at least a portion of the one or more fourth jamb elements and/or at least a portion of the first head jamb element overlaps at least a portion of the one or more second head jamb elements. 
     Optionally, the first jamb element is substantially parallel to the second jamb element, and the one or more third jamb elements are substantially parallel to the one or more fourth jamb elements. Optionally, the first head jamb element is substantially perpendicular to the first jamb element and the second jamb element, and the one or more second head jamb elements are substantially perpendicular to the at least one third jamb element and the at least one fourth jamb element. 
     Optionally, the first head jamb element connects the first jamb element and the second jamb element at respective first ends of the first jamb element and the second jamb element, and at least one of the one or more second head jamb elements connects at least one of the one or more third jamb elements and at least one of the one or more fourth jamb elements at respective first ends of the one third jamb element and the one fourth jamb element. 
     Optionally, the first door frame casing is substantially perpendicular to the first jamb element, the second jamb element and the first head jamb element, and the second door frame casing is substantially perpendicular to the one or more third jamb elements, the one or more fourth jamb elements and the one or more second head jamb elements. 
     Optionally, the one or more third jamb elements comprise a first inner jamb element and a first outer jamb element substantially parallel to the first inner jamb element, the one or more fourth jamb elements comprise a second inner jamb element and a second outer jamb element substantially parallel to the second inner jamb element, the one or more second head jamb elements comprise an inner head jamb element between the first inner jamb element and the second inner jamb element, and an outer head jamb element substantially parallel to the inner head jamb element and between the first outer jamb element and the second outer jamb element, and in each of the plurality of overlapping positions, the first jamb element fits between the first inner jamb element and the first outer jamb element, the second jamb element fits between the second inner jamb element and the second outer jamb element and/or the first head jamb element fits between the inner head jamb element and the outer head jamb element. 
     Optionally, the inner head jamb element connects the first inner jamb element to the second inner jamb element at corresponding first ends of the first inner jamb element and the second inner jamb element. Optionally, a first space is provided between a first end of the first outer jamb element and a corresponding first end of the outer head jamb element, and a second space is provided between a first end of the second outer jamb element and a corresponding second end of the outer head jamb element. 
     Optionally, at least one of the first inner jamb element, the second inner jamb element and the inner head jamb element comprises a plurality of through holes for the insertion of fastening means. Optionally, at least one of the first inner jamb element, the second inner jamb element and the inner head jamb element is substantially planar and comprises a channel in which the through holes are formed. Optionally, when the first inner jamb element comprises a channel, the channel is configured to receive a locating ridge of a hinge, the locating ridge configured to resist lateral loading applied to the hinge when installed in the channel. Optionally, the through holes are formed substantially in a line parallel to an edge of the first inner jamb element, the second inner jamb element and/or the inner head jamb element opposite the second door frame casing. Optionally, the line is closer to the edge than to the second door frame casing. Optionally, the first outer jamb element, the second outer jamb element and/or the outer head jamb element each comprise a plurality of through slots configured to correspond to the plurality of through holes. Optionally, the first jamb element, the second jamb element and/or the first head jamb element each comprise a plurality of through slots configured to correspond to the plurality of through holes when the first frame member is assembled with the second frame member to form the door frame. 
     Optionally, the first inner jamb element, the second inner jamb element and the inner head jamb element each comprise a lip portion along an edge opposite the second door frame casing to form an architrave. Optionally, the first inner jamb element, the second inner jamb element and the inner head jamb element each comprise a first stepped portion at an edge proximal the second door frame casing. Optionally, the first outer jamb element, the second outer jamb element and the outer head jamb element each comprise a second stepped portion at an edge proximal the second door frame casing. 
     A dimension of each of the plurality of through slots parallel to an edge of the first inner jamb element, the second inner jamb element or the inner header element opposite the second door frame casing may be larger than the diameter of the through holes. 
     A dimension of each of the plurality of through slots perpendicular to an edge of the first inner jamb element, the second inner jamb element or the inner header element opposite the second door frame casing may be larger than the diameter of the through holes. 
     In accordance with an aspect of the disclosure there is provided a door set comprising a door leaf, a hinge member and the door frame assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the disclosure shall now be described with reference to the drawings in which: 
         FIG. 1  shows an existing door set; 
         FIG. 2  shows a first member of a door frame assembly that is an embodiment of this disclosure; 
         FIG. 3  shows a second member of the door frame assembly; 
         FIG. 4  shows the door frame assembly; 
         FIG. 5  shows a plan view of the second member; 
         FIG. 5A  shows a cross-sectional view through part of the door frame assembly; 
         FIG. 6  shows a perspective view of the second member; 
         FIG. 7  shows a header element of a member of the door frame assembly; 
         FIG. 8  shows a perspective view of the second member; 
         FIG. 9  shows a cross-sectional view through an assembled door set. 
     
    
    
     Throughout the description and the drawings, like reference numerals refer to like parts. 
     DETAILED DESCRIPTION 
     The present disclosure relates to a door frame assembly assembled from two members, each of which provides one side of the assembled door frame. The two members are inserted into an opening in a wall from opposite sides of the wall. The two members slot together and are fastened to each other to hold them in place. The assembled door frame allows the installation of a two-way swing hinge that holds a door leaf that can open both ways with respect to the door opening. 
       FIG. 1  shows a conventional door set  100 . The door set  100  comprises a leaf  102  and a frame  104 . The frame  104  is comprised of a header  106  a hinge jamb  108   a  and a lock jamb  108   b . The jambs  108  are parallel to each other and are connected by the header  106 , which is perpendicular to the jambs  108 . The frame  104  defines a door opening  112  which is closed by the leaf  102  when the door is closed. The leaf  102  is mounted to the hinge jamb  108   a  by two hinges  110 . The frame  104  also comprises a stop  114  that runs around the inner perimeter of the frame  104  and is configured to prevent the door leaf from rotating through the opening  112 . A two-way door, that is able to open in both directions, would not have a stop  114 . 
       FIGS. 2 to 4  show a door frame assembly  200  that can be fitted to a door opening in a wall according to an example of the disclosure.  FIG. 2  shows a first frame member  202  comprising a hinge jamb element  204 , a lock jamb element  206 , a header element  208  and a casing  210 . The hinge jamb element  204  and the lock jamb element  206  are substantially perpendicular to the header element  208  in order to correspond to the jambs  108  and header  106  of a frame  104 . The header element  208  is joined at one end to the hinge jamb element  204  and at the opposite end to the lock jamb element  206 . The casing  210  is arranged along corresponding edges of the hinge jamb element  204 , the lock jamb element  206  and the header element  208 . Each of the hinge jamb element  204 , the lock jamb element  206 , the header element  208  and the casing  210  are substantially planar. The casing  210  is arranged perpendicularly to the hinge jamb element  204 , the lock jamb element  206  and the header element  208 . The first frame member  202  is arranged to be inserted into a door opening from one side of the door opening. 
       FIG. 3  shows a second frame member  302 . During assembly of the frame assembly  200 , the second frame member  302  is inserted into the door opening from the opposite side of the opening than the first frame member  202 . The second frame member  302  comprises a first hinge jamb element  304 , a first lock jamb element  306 , a first header element  308  and a casing  316 . The first hinge jamb element  304 , the first lock jamb element  306 , the first header element  308  and the casing  316  of the second frame member  302  correspond substantially in form and dimension to the hinge jamb element  204 , the lock jamb element  206 , the header element  208  and the casing  210  of the first frame member  202 . However, the spacing between the first hinge jamb element  304  and the first lock jamb element  306  of the second frame member  302  is slightly smaller than the corresponding spacing on the first frame member  202 . Similarly, the length of the first hinge jamb element  304  and the first lock jamb element  306  of the second frame member  302  is slightly less than the corresponding length on the first frame member  202 . In this way, when the first frame member  202  and the second frame member  302  are placed together, the hinge jamb element  204 , the lock jamb element  206  and the header element  208  of the first frame member  202  fit outside the first hinge jamb element  304 , the first lock jamb element  306  and the first header element  308  of the second frame element  302  with respect to the door opening. The fit is a clearance fit such that a space is provided between corresponding elements of the first frame member  202  and the second frame member  302  as the first frame member  202  and the second frame member  302  are placed together. Alternatively, the fit may be a sliding fit, such that there is contact between corresponding elements of the first frame member  202  and the second frame member  302  as the first frame member  202  and the second frame member  302  are placed together. 
     The second frame member  302  also comprises a second hinge jamb element  310 , a second lock jamb element  312  and a second header element  314 . The second hinge jamb element  310  and the second lock jamb element  312  are attached to the first hinge jamb element  304  and first lock jamb element  306  respectively. The second hinge jamb element  310  and the second lock jamb element  312  each have a principal plane and an offset section for connection to the first hinge jamb element  304  and first lock jamb element  306 . The principal planes of the second hinge jamb element  310  and the second lock jamb element  312  are arranged parallel to and outside the first hinge jamb element  304  and first lock jamb element  306  respectively with respect to the door opening. The second header element  314  is attached to the first header element  308 . The second header element  314  also has a principal plane and an offset section for connection to the first header element  308 . The principal plane of the second header element is arranged parallel to and above the first header element  308  with respect to the door opening. 
     The spacing between the principal planes of the second hinge jamb element  310  and the second lock jamb element  312  of the second frame member  302  is slightly larger than the corresponding spacing on the first frame member  202 . Similarly, the height of the principal plane of the second header element  314  of the second frame member  302  from the ground is slightly larger than the height of the header element  208  of the first frame member  202 . In this way, gaps are provided between the jamb elements and header elements of the second frame member  302  into which the jamb elements and header element of the first frame member  202  fit when the first frame member  202  and the second frame member  302  are assembled together. The fit is a clearance fit such that a space is provided between corresponding elements of the first frame member  202  and the second frame member  302  as the first frame member  202  and the second frame member  302  are placed together. Alternatively, the fit may be a sliding fit, such that there is contact between corresponding elements of the first frame member  202  and the second frame member  302  as the first frame member  202  and the second frame member  302  are placed together. The correspondence between the jamb elements and header element of the first frame member  202  and the gaps provided by the second frame member  302  help to locate the two frame members together and maintain them in relative position. The second hinge jamb element  310 , the second lock jamb element  312  and the second header  314  of the second frame element  302  are not directly connected to each other. 
     The composite parts of the first frame member  202  (the jamb elements  204 ,  206 , header element  208  and casing  210 ) are formed separately and welded together. Similarly, the composite parts of the second frame member  302  (the jamb elements  304 ,  306 ,  310 ,  312 , header elements  308 ,  314  and casing  316 ) are formed separately and welded together. Alternatively, the parts may be joined by adhesive or any suitable attachment means. Alternatively, the first frame member  202  and the second frame member  302  may each be integrally formed. In this embodiment, the first frame member  202  and the second frame member  302  are made of steel. Other materials which can be formed into the desired shapes which are also strong and rigid are also envisaged. 
       FIG. 4  shows the assembly of the first frame member  202  and the second frame member  302  to make the frame assembly  200 . The jamb elements  204  and  206  and header  208  of the first frame member  202  fit inside the gaps provided by the jamb elements  304 ,  306 ,  310  and  312  and the header elements  308  and  314  of the second frame member  302 , as previously described. A door opening  402  is defined by the inner surfaces of the first hinge jamb element  304 , first lock jamb element  306  and first header element  308  of the second frame member  302 . The casings  210  and  316  are visible from either side of the wall in which the door opening  402  is formed. Such a door frame assembly  200  allows a two-way hinge and leaf to be attached, as will be explained in relation to  FIG. 9 . 
       FIG. 5  shows a top view of the second frame member  302 . In this figure, the second hinge jamb element  310 , second lock jamb element  312  and second header element  314  shown in  FIG. 3  have been cut away. As such, the first header element  308  can be seen in plan view. The cross-sectional profile of the first hinge jamb element  304  and the first lock jamb element  306  can also be seen and is also shown in  FIG. 5A . With continued reference to  FIG. 5 , the first hinge jamb element  304 , the first lock jamb element  306  and the first header element  308  have the same cross-sectional profile. 
     The first header element  308  has a principal plane defined by a first web portion  504  and a second web portion  510 . The first header element  308  also has a stepped portion  502  and channel  506 , which extend from the principal plane of the first header element  308  away from the door opening. This is shown by the offset of the stepped portion  502  and the channel  506  from the first web portion  504  and the second web portion  510 . The stepped portion  502  is formed at an edge of the first header element  308  that connects to the casing  316 . This is to allow the fixing of an anti-barricade doorstop to the door frame assembly  200 . The channel  506  is square or rectangular in cross-section. Other cross-sections which allow insertion of fastening elements without interference with the principal plane are also envisaged. The first header element  308  also has a lip portion  512  attached to the second web portion  510 , which is discussed in more detail in relation to  FIG. 5A . 
     The channel  506  has a plurality of through holes  508  formed in the channel face parallel to the principal plane of the first header element  308 . The through holes allow the insertion of fastening means, for example, screws and/or bolts. These are used to fasten the first frame member  202  to the second frame member  302  when the frame assembly  200  is assembled. 
       FIG. 5A  shows a cross-section of the first header element  308  through the section A-A shown in  FIG. 5 . The lip portion  512  has a first part  514  that is perpendicular to the second web portion  510  and a second part  516  that is parallel to the second web portion  510  and spaced from it by the first part  514 . The casing  316  also has a casing part  518  that is perpendicular to the casing  316 . The lip portion  512  and the casing part  518  serve to form an architrave on either side of the door frame assembly  200 . As discussed, this cross-sectional profile is the profile of the first hinge jamb element  304  and the first lock jamb element  306  as well as the first header element  308   
       FIG. 6  shows a perspective view of the second frame member  302  with the second hinge jamb element  310 , second lock jamb element  312  and second header element  314  cut away. The offset of the channel  506  from the first web portion  504  and the second web portion  510  allows the insertion of fastening elements into through holes  508  without interference with the principal plane of the frame element  302 . As the cross-sectional profile is consistent along the first hinge jamb element  304 , first header element  308  and first lock jamb element  306 , fastening is allowed along all three sides of the door frame assembly  200 . Therefore, a hinge and leaf can be attached to the first hinge jamb element  304 , flush with the first web portion  504  and second web portion  510 , and without interference from fastening elements used to hold the first frame member  202  and the second frame member  302  together. This will be shown in more detail in relation to  FIG. 9 . 
       FIG. 7  shows a detailed illustration of the second header element  312  of the second frame member  302 . The second header element  312  has a web  704  that defines the principal plane of the second header element  312 . The second header element  312  also has an offset portion  702  at the edge closest to the casing  316 . The offset portion  702  serves to space the second header element  312  from the second frame member  302  to allow the correct gap for first frame member  202  to locate into. The web  704  has a plurality of through slots  706  arranged along a line parallel to the edge  708  of the second header element opposite the offset portion  702 . The slots  706  are arranged to correspond to the through holes  508  in the first header element  308 . The slots  706  are arranged closer to the edge  708  than to the offset portion  702  to line up with the holes  508  when the second frame member  302  is assembled. The slots  706  are arranged to have a width  710  that is larger than the diameter of the through holes  508 . This provides a clearance for fastening elements to be inserted when the second frame member  302  is installed. The slots  706  are also arranged to have a depth  712  that is larger than the diameter of the through holes  508  in the first header element  308 . This also provides a clearance for fastening elements to be inserted when the second frame member  302  is installed. This configuration applies equally to the second hinge jamb element  310  and the second lock jamb element  312 . 
       FIG. 8  shows a perspective view of the second frame member as shown in  FIG. 6  with the second hinge jamb element  310  (not visible), second header element  314  and second lock jamb element  312  present. It can be seen that the slots  706  correspond to the holes  508  provided in the channel  506  of the first hinge jamb element  304 , first header element  308  and first lock jamb member  306 . 
     The jamb elements  204 ,  206  and header element  208  of the first frame member  202  do not have any through holes, and fastening elements  904  penetrate the elements of the first frame member  202  during assembly. This provides flexibility to the thickness of the wall in which the frame is to be assembled, as there is no requirement for specific alignment of the through holes  508  and through slots  706  of the second frame member with any corresponding holes or slots in the first frame member  202 . 
     The assembly can be seen in  FIG. 9 , which is a view of a door set  900  through the cross-section B-B shown in  FIG. 8  once the first frame member  202  and the second frame member  302  have been assembled together. The first frame member  202  and the second frame member  302  are fastened together using a fastening element in the form of a nut and bolt  904  inserted through the corresponding through holes  508  and through slots  706  of the second frame member  302  and penetrating the first jamb element  204  of the first frame member  202 . 
     As discussed above, the cross-sectional profile of the first hinge jamb element  304 , first header element  308  and first lock jamb element  306  of the second frame member  302  allows a leaf  102  and hinge  906  to be attached to the frame assembly  200  without interference from the fastening elements used to hold the first frame member  202  and the second frame member  302  together. This profile also allows the insertion of a hinge  906  with a ridge element  902  that acts against lateral loading of the door set  900  when it is fully assembled. The ridge element  902  is received in the channel  506  of the first hinge jamb element  304 . When a lateral load is applied to the door leaf  102 , the ridge element  902  engages with the lateral surfaces of the channel  506  and acts against the lateral load. This helps to prevent a patient forcing their way through the door by removing the door leaf  102  from the frame assembly  200  by lateral force. The hinge  906  may be a hinge as described in UK Patent No. 2516093. 
     During assembly, the first frame member  202  is inserted into a door opening in a wall from one sides of the wall. The second frame member  302  is inserted into the door opening from the opposite side of the wall to the first frame member  202 . The jamb elements  202  and  204  of the first frame member  202  slot into the gaps between the jamb elements  304 ,  306 ,  310  and  312  of the second frame member  302 . The header element  208  of the first frame member  202  slots into the gap between the header elements  308  and  314  of the second frame member  302 . This allows the two frame members  202  and  302  to be located together. The degree to which the elements of the first frame member  202  overlap those of the second frame member  302  when slot into the gaps in the second frame member  302  is adjustable based on the thickness of the wall. Once in position, fastening elements in the form of nuts and bolts  904  are inserted through the through holes  508  and through slots  706  of the second frame member  302  and through the jamb elements of the first frame member  202  to hold the two frame members together. The two-way swing hinge  906  that holds the door leaf  102  is installed on the assembled door frame assembly  200  to provide the completed door set  900 . The two-way swing hinge  906  allows the door to open both ways with respect to the door opening. 
     In an alternative configuration, the first frame member  202  also may have through slots in its jamb elements  204  and  206  and its header element  208  which correspond to the through holes  508  and through slots  706  in the corresponding elements of the second frame member  302 . In this way, when the first frame member  202  and second frame member  302  are assembled such that the jamb and header elements  204 ,  206  and  208  of the first frame member  202  slot into the gaps between the jamb elements  304 ,  306 ,  310  and  312  and the header elements  308  and  314  of the second frame member  302 , as previously described, the through holes  508  and through slots  706  of the second frame member  302  are aligned with the through holes in the first frame member  202  such that the two frame members can be fastened together. 
     The door frame assembly  200  and door set  900  disclosed above provide a simple assembly for framing a door opening. The relative positioning of the jamb and header elements of the two frame members  202  and  302  helps to locate the two frame members  202  and  302  together and maintain them in relative position. The two frame members  202  and  302  can be slotted together at varying degrees of overlap in order to take account of the thickness of the wall in which the frame assembly  200  is being installed. The profile of the jamb elements means that the fastening elements can be inserted whilst leaving space for a hinge to be attached to the frame without interference from the fastening elements. This profile also allows the insertion of a hinge with a ridge element that acts against lateral loading of the door set  900  when it is fully assembled. This can prevent patients in a psychiatric ward in which the door set  900  is implemented from trying to force their way in or out of the doorway. Such a hinge may be a two-way swing hinge that holds a door leaf that can open both ways with respect to the door opening. Such a hinge can have a single leaf that opens both ways in order to provide as simple a structure as possible. The two-way opening action of the door also prevents by a patient barricading themselves on one side of the door. Such a hinge may also have anti-ligature functionality to reduce, or prevent entirely, the possibility of a patient causing themselves harm by using part of the door set  900 . 
     Various modifications may be made to the described embodiments without departing from the scope of the invention as defined by the accompanying claims.