Patent Abstract:
A building fenestration that reduces the amount of time, effort and expense associated with installing a jamb in a rough opening of a building panel structure includes a jamb positioned plumb in the opening, the jamb having outwardly facing planar surfaces, at least one bracket receiving slot on at least one of the outwardly facing planar surfaces of the jamb, and a bracket having first and second legs at right angles to each other, the first leg of the bracket received in the bracket receiving slot and the second leg of the bracket fastened to the building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate.

Full Description:
FIELD OF THE INVENTION 
       [0001]    This invention relates to the field of fenestration including the mounting of doors, windows, skylights, and the like in building walls, ceilings and the like, and more particularly to a jamb mounting assembly that reduces the amount of labor, time and materials needed for installation of a jamb. 
       BACKGROUND OF THE INVENTION 
       [0002]    Conventional methods for installing a door jamb, window jamb or the like in a building wall or roof have generally involved positioning the jamb in a rough opening and filling the gaps between framing members of the opening and the jamb with wood shims. Properly trimming and installing the shims between the jamb and the frame defining the opening requires a considerable amount of time, skill and effort to properly fit the jamb in the opening so that the jamb is plumb. After the shims have been properly positioned, nails are driven through the jamb and the shims into the supporting framing members defining the opening. Thereafter, protruding pieces of the shims, if any, are cut flush with the edge of the jamb. 
         [0003]    It is of course desirable to eliminate the use of shims and to simplify jamb installation. To this end, numerous efforts have been directed toward simplified, shimless jamb mounting systems. While many of these systems have very substantially reduced the amount of time and effort needed to install a jamb in a building panel structure, such as a wall or roof, further improvements are desirable. In particular, it would be desirable to reduce the number of fasteners needed for jamb installation and to provide simpler, easier to manufacture and less expensive jamb mounting brackets, and to provide a jamb mounting assembly that may be at least partially pre-installed on the jamb prior to shipment from the factory. 
       SUMMARY OF THE INVENTION 
       [0004]    In one aspect of the invention, a building fenestration is provided which includes a jamb positioned in an opening defined by a building panel structure, at least one bracket receiving slot on an outwardly facing planar surface of the jamb, and a bracket having first and second legs at a right angle to each other, the first leg of the bracket received in the bracket receiving slot and the second leg of the bracket fastened to the building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate defined on or attached to the jamb. In accordance with this aspect of the invention, the jamb may be mounted in a building panel opening by positioning the jamb in the opening with one or more bracket receiving slots pre-defined or installed on outwardly facing planar surfaces of the jamb, the jamb being positioned so that it is plumb with the opening, inserting the first leg of the bracket into the bracket receiving slot and fastening the second leg of the bracket to the building panel structure. 
         [0005]    In accordance with another aspect of the invention, there is provided a jamb mounting assembly comprising a jamb having planar outwardly facing peripheral surfaces; a bracket receiving slot on at least one of the planar outwardly facing peripheral surfaces of the jamb; and a bracket having first and second legs at a right angle to each other, the first leg of the bracket configured to be received in the bracket receiving slot and the second leg of the bracket configured for attachment to a building panel structure, wherein the bracket receiving slot is defined between one of the outwardly facing planar surfaces of the jamb and a substantially flat plate. In accordance with this aspect of the invention, installation is further simplified by providing a jamb having premounted or pre-defined bracket receiving slots, whereby installation of the jamb may be achieved by steps generally involving positioning of the jamb in an opening defined in a building panel structure, the jamb being positioned plumb with the opening, inserting the first leg of a panel bracket into each of the bracket receiving slots and fastening the second leg of each bracket to the building panel structure. 
         [0006]    In accordance with another aspect of the invention, there is provided a jamb mounting assembly comprising a substantially flat plate adapted to be fastened to a planar outwardly facing peripheral surface of a jamb to define a bracket receiving slot, and a bracket having first and second legs at a right angle to each other, the first leg of the bracket configured to be received in the bracket receiving slot, and the second leg of the bracket configured for attachment to a building panel structure. The jamb mounting assembly in accordance with this aspect of the invention may be used on generally any jamb having planar outwardly facing peripheral surfaces. 
         [0007]    In another aspect of the invention, there is provided a bracket for mounting a jamb to a wall with or without a bracket receiving slot. The bracket includes first and second legs at a right angle to each other and tangs projecting at a right angle from one of the legs to facilitate fastening of the bracket to the jamb. 
         [0008]    In a further aspect of the invention, there is provided another bracket for mounting a jamb to a wall with or without a bracket receiving slot. This bracket includes first and second legs at a right angle to each other and tabs projecting at a right angle from one of the legs to facilitate fastening of the bracket to the jamb. 
         [0009]    These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a fragmentary perspective view of a rough opening in a building wall that is about to receive a door jamb. 
           [0011]      FIG. 2  is an enlarged fragmentary perspective view of the door jamb shown in  FIG. 1  to illustrate certain details. 
           [0012]      FIG. 3  is fragmentary, side view of the door jamb show in  FIG. 2 . 
           [0013]      FIG. 4  is a perspective view of a bracket for securing a jamb in a rough opening. 
           [0014]      FIG. 5  is fragmentary, front elevational view of a jamb installed in a rough opening employing the bracket shown in  FIG. 4 . 
           [0015]      FIG. 6  is a fragmentary side view of an alternative embodiment of a jamb having an integrally formed bracket receiving slot. 
           [0016]      FIG. 7  is a perspective view of an alternative bracket for securing a jamb in a rough opening. 
           [0017]      FIG. 8  is a fragmentary perspective view of the bracket shown in  FIG. 7  being used to secure a jamb in a rough opening. 
           [0018]      FIG. 9  is a fragmentary perspective view of another alternative bracket being used to secure a jamb in a rough opening. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0019]    Shown in  FIG. 1  is a rough opening  10  in a wall structure  12  formed by studs  14 , and header  16  supported by liner members  18 . Wall structure  12  may be covered with drywall panels  20  or the like to provide a finished wall, either before or after installation of jamb  22  in accordance with the invention. 
         [0020]    The jamb mounting assemblies of this invention may be used for generally any type of building fenestration, including doors, windows, skylights and the like. In general, such fenestrations may be provided in accordance with this invention in various building panel structures, including exterior and interior wall structures, and roof structures. 
         [0021]    As shown in greater detail in  FIG. 2 , outwardly facing peripheral surfaces  23  of jamb  22  are provided with panel bracket receiving slots  26 . As shown in  FIGS. 2 and 3 , panel bracket receiving slot  26  may be defined between one of the outwardly facing planar surfaces  23  of jamb  22  and a substantially flat plate  28 . The expression “substantially flat” as used to describe plate  28  is meant to encompass the fact that plate  28  is formed or bent slightly to allow flush mounting of opposite ends  30  and  31  of plate  28  to surface  23  of jamb  22  while allowing a sufficient gap between the ends of plate  28  to define a slot  26  into which a leg of a bracket may be received. Alternatively, as shown in  FIG. 6 , plate  28 A can be formed as an integral section of the material used to fabricate jamb  22 . This may be achieved such as by cutting and stamping operations. Thus, bracket receiving slot  26  may be defined by pre-installed plates  28  fastened to surface  23  of jamb  22  with fasteners  32 ,  34  (screws, rivets or the like) by the jamb manufacturer; attached by the jamb installer; or integrally pre-formed on jamb  22 . 
         [0022]    After installation, pre-installation or integral forming of bracket receiving slots  26  on jamb  22 , jamb  22  is positioned in plumb in opening  10 . Thereafter, a bracket  34  is used to secure jamb  22  in plumb in rough opening  10 . Bracket  34  includes a first leg  36  and a second leg  38  which is at a right angle to leg  36 . A forward edge  40  of first leg  36  is inserted into bracket receiving slot  26  until second leg  38  is flush against finish panels  20  (e.g., drywall or the like) or flush against liner  18  or stud  14 . Thereafter, each bracket  34  may be secured to the building panel structure (e.g., wall structure or ceiling structure) with a single fastener (such as a screw or nail). However, bracket  34  may be configured for attachment with multiple fasteners if desired. In the illustrated embodiment, a single fastener aperture  42  is provided through second leg  38  of bracket  34 . 
         [0023]    In those cases in which bracket  34  is attached directly to studs  14  or liner member  18 , drywall or other finish wall material  20  may be subsequently installed over bracket  34 . In the case where bracket  34  is installed over drywall or other finish wall material  20 , exposed surfaces of leg  38  of bracket  34  may be primed, covered with spackle or the like to facilitate application of paint, wallpaper or the like. Thus, the invention facilitates installation of a door or window jamb in a wall or installation of a skylight in a roof generally any time after framing of the walls or roof have been completed. After jamb  22  and finish wall material  20  have been installed, various trim options may be employed to cover the gap between jamb  22  and the wall and to conceal brackets  34 . If desired, insulation (such as foam or glass fiber) may be inserted into the gap between jamb  22  and the wall prior to adding the finish trim. 
         [0024]    As can be seen by reference to  FIG. 2 , flat plate  28  can be located entirely between corners  41  and  42  of the outwardly facing planar surface  23  of jamb  22 . This arrangement allows exceptional flexibility with respect to the use of exposed trim for concealing the gap between rough opening  10  and surfaces  23  of jamb  22 . Further, because plate  28  is substantially flat and/or is located entirely between the edges of the outwardly facing planar surfaces  23  of jamb  22 , pre-installed plates  28  have a very low profile that should not interfere with or require modification to packaging materials or shipping procedures for pre-hung doors, pre-hung windows and the like. 
         [0025]    In the illustrated embodiment, the details of which are shown in  FIG. 2 , flat plate  28  includes a tab  48  which projects from a lateral edge of flat plate  28  and which extends through an aperture  50  defined in leg  38  of bracket  34  ( FIG. 4 ) when leg  36  of bracket  34  is inserted into slot  26 . As shown in  FIG. 5 , tab  48  may optionally be bent at a right angle flush with the exposed surface of leg  38  or bracket  34 . 
         [0026]    As shown in  FIG. 4 , leg  38  of bracket  34  may be provided with one or more scribe lines  49  that may be aligned with a plumb line  51  ( FIG. 5 ) drawn on the wall, liner  18 , stud  14  or the like. 
         [0027]    Leading edge  40  of leg  36  of bracket  34  may have a tapered shape that becomes progressively narrower away from second leg  38 , and may be curved to facilitate easier insertion of leg  36  of bracket  34  into slot  26 . 
         [0028]      FIG. 7  shows an alternative bracket  50  having a first leg  36  and a second leg  38 , in which tangs  52  are provided. Tangs  52  project at a right angle from second leg  38  along a plane parallel to first leg  36  in the direction of leg  36 , and have sharp or pointed ends  54  that allow bracket  50  to penetrate an edge  56  of jamb  22  as shown in  FIG. 8  to firmly secure bracket  50  to jamb  22 . Bracket  50  is otherwise generally similar to and used in a similar way to bracket  34 . However, bracket  50  may be used either with or without plate  28  or  28 A. 
         [0029]      FIG. 9  shows another alternative bracket  60  having a first leg  36  and a second leg  38 , in which fastener tabs  62  are provided. Tabs  62  projects at a right angle from second leg  38  along a plane parallel to first leg  36  in a direction opposite leg  36 . Tabs  62  may be provided for firmly securing bracket  60  to outwardly facing planar surface  23  of jamb  22 . Bracket  60  is otherwise generally similar to and used in a similar way to bracket  34 . However, bracket  60  may be used either with or without plate  28  or  28 A, and is normally used before wall covering  20  is installed. 
         [0030]    The various aspects of this invention provide a simple, fast, effective way to secure jambs to building panel structures such as wall structures and roof structures. In accordance with certain aspects of the invention, installation is further simplified by integrally forming or factory installing structure to define a bracket receiving slot, whereby after the jamb has been properly positioned in a rough opening, installation is completed by simply sliding a bracket into each of the bracket receiving slots provided and fastening each bracket to the building panel structure. The invention may be used with either new construction or during remodeling or renovation, and with or without finish material (e.g., drywall) applied to the building panel structure. Because the structure defining the bracket receiving slot is separate from the brackets until installation is nearly complete, bracket  34  is self-adjusting to various wall thicknesses with or without finish material applied to the building panel structure. For a typical installation, only one screw per bracket is needed. Thus, for a typical pre-hung door jamb installation, after proper positioning of the door and door jamb in a rough opening, installation is completed by merely inserting a bracket into each of the seven bracket receiving slots, and securing each of the brackets to the wall structure, such as with a single fastener (e.g., a screw). 
         [0031]    Another advantage with the substantially flat configuration of plate  28  or  28 A is that it is very inexpensive, and therefore can be pre-installed or pre-formed on every jamb shipped from a manufacturer without interfering with an installer&#39;s ability to either employ brackets  34  as disclosed herein or to employ conventional installation methods if desired. In accordance with this aspect of the invention, incorporating pre-formed or pre-installed plates  28  or  28 A, manufacturers are provided with control over where and how often attachment of a jamb takes place, allowing positioning and placement of the jamb bracket to be controlled by the manufacturer. Because of the very simple, low profile and compact design of the structure ( 28  or  28 A) defining the bracket receiving slots  26 , structure  28  or  28 A does not interfere with or require any modification of typical shipping and delivery methods that are currently employed. The invention allows full insulation of the cavity defined between a jamb and a building panel structure because attachment of the jamb may be achieved by securement of brackets  34  to the interior side of an exterior wall. This allows the cavity to be filled, usually from the inside, with fiberglass or foam insulation to increase energy efficiency of the installation as whole, making the total unit more energy efficient in the completed fenestration. Because the installation is very simple and self-adjusting, poor workmanship issues are eliminated or very substantially reduced, decreasing warranty issues. 
         [0032]    The above description is considered that of the preferred embodiment(s) only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiment(s) shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.

Technology Classification (CPC): 4