Patent Abstract:
A door assembly includes a door frame having a horizontal header along the top thereof. A firestop extends downwardly from the header, the firestop has a plurality of sides defining a channel therein. The firestop has an at least partially open side to allow the channel to be open and receive a closer assembly. A door closer assembly is coupled to the door. The door closer assembly has a biasing assembly and an arm having a first end and a second end. The first end is rotatably coupled to the biasing assembly and is slidably coupled to the channel.

Full Description:
TECHNICAL FIELD 
     The present invention relates generally to an entry door for a building and, more specifically, to a building door having a door closer guide track formed as a portion of the firestop of the door. 
     BACKGROUND OF THE INVENTION 
     Installing doors into buildings under construction typically requires the assistance of various tradesmen. For example, for one opening, tradesmen such as carpenters, painters, glaziers, electricians and drywallers are required to complete the installation of a door. Other tradesmen may also be used for the installation of a door closer. 
     One problem associated with the use of tradesmen for completing the installation of a door is that alignment of the devices may have to be verified using several tradesmen. Tradesmen are expensive and therefore it is desirable to minimize adjustment and alignment procedures on the construction site. 
     Door closers are commonly used on commercial doors. Door closers may take many forms. Typically, door closers are mounted on the door and extend to the door frame. A spring, cam or other biasing members urges the door shut through the use of an arm. 
     Another type of door closer provides a slider mortised in the door frame that allows one end of the door closer arm to slide therein. One problem with mortising a track within the door frame is that further tradesmen are required on the construction site to mortise the closer track into the door frame. Such an operation is labor intensive and therefore costly. 
     Firestops are typically provided within a door frame. Many times the door frames are metal and have an integrally formed firestop therearound. The firestop is typically an extension of about five-eighths of an inch that extends into the door opening against which the door closes. The firestop along with weather stripping eliminates the air gap between the door and the door frame. The firestop may be integrally formed with the door frame or may be assembled as a separate add on piece. 
     It would therefore be desirable to provide a door assembly that reduces the cost of the installation of the door while incorporating features of the door closer assembly therein. 
     SUMMARY OF THE INVENTION 
     The present invention reduces the cost of assembly of the door by providing a firestop having a novel design which incorporates a slider channel therein for slidably receiving one end of the slider assembly. 
     In one aspect of the invention, a door assembly includes a door frame having a horizontal header along the top thereof. A firestop extends downwardly from the header, the firestop has a plurality of sides defining an open channel therein. The firestop has an at least partially open side to define the open channel. A door is rotatably mounted within the door frame. A door closer assembly is coupled to the door. The door closer assembly has a biasing assembly and an arm having a first end and a second end. The first end is rotatably coupled to the biasing assembly and is slidably coupled to the channel. 
     In a further aspect of the invention, a method of forming a door assembly comprises: 
     mounting a firestop to a header of a door frame, said firestop having an at least partially open side and a channel defined therein; 
     mounting a closer assembly having an arm extending therefrom to a door; and 
     slidably coupling the arm to the channel. 
     One advantage of the invention is that the cost of assembling the door by tradesmen is reduced because the door closer assembly may be mounted in a factory environment. This leads to another advantage in which the door assembly can be aligned and tested in the assembled position. 
     A further advantage of the invention is that doors without closer assemblies according to the present invention may be retrofitted to provide a door closer according to the present invention. 
     Other advantages and features of the present invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view of a door frame defining an opening for use according to the present invention. 
     FIG. 2A is a cross-sectional view of a door in a closed position according to the present invention. 
     FIG. 2B is a cross-sectional view of a door in an open position according to the present invention. 
     FIG. 3 is a cross-sectional view of a firestop mounted to a door frame header according to the present invention. 
     FIG. 4 is a cross-sectional view of a door having a door closer in position with a firestop mounted to a header of a door frame according to the present invention. 
     FIGS. 5A,  5 B, and  5 C are elevational views of a slider used in the present invention. 
     FIG. 6 is a cross-sectional view of an assembled closer assembly according to the present invention. 
     FIG. 7 is a top view of a closer assembly having a closer arm. 
     FIG. 7A is a top view of a closer assembly similar to FIG. 7 using an alternative closer arm. 
     FIG. 8 is an elevational view of a door having an externally mounted closer according to the present invention. 
     FIG. 9 is a cross-sectional view of an alternative embodiment of a firestop according to the present invention. 
     FIG. 10 is a cross-sectional view of a retrofit door according to the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     In the following figures, the same reference numerals will be used to illustrate the same components in the various views. The present invention is described with respect to commercial doors and has various geometrically shaped frame, track and other components. These shapes are illustrated but not meant to be limiting unless otherwise specified in the claims. 
     Referring now to FIG. 1, a door  10  is illustrated having a frame  12  around its perimeter. Frame  12  comprises a horizontal header  14  and vertical jambs  16 . Horizontal header  14  and vertical jambs  16  may be formed of a variety of materials including wood, metal or a composite material. Preferably in commercial door environments, horizontal header  14  and vertical jambs  16  are formed from metal. 
     Door  10  has a pair of faces  18 A and  18 B, which may be referred to as inner and outer, respectively. A portion of outer face  18 B is cut away to reveal the core of door  10 . A number of spacers  20  are typically incorporated to hold inner and outer faces  18 A,  18 B a predetermined distance apart. Spacers  20  are commonly used in the industry. Spacers  20  may be formed from various materials including cardboard, wood blocks, expanded polystyrene, metal, honeycomb, or fire resistant material. A void  22  is formed between spacers  20  and outer faces  18 A. Void  22  may be sized to receive an integrated door closer to urge the door into a closed position as will be further described below. 
     Door frame  12  has firestops  24 A and  24 B positioned to extend into the door opening. Firestop  24 A is positioned on horizontal header  14 . Firestops  24 B are positioned on jambs  16 . Firestops  24 A,  24 B closes the air gap between door  10  and frame  12 . 
     Referring now to FIGS. 2A and 2B, door  10  is shown in various positions. In FIG. 2A, door  10  is illustrated in a closed position while in FIG. 2B door  10  is illustrated in an open position. A hinge  26  is used to rotatably couple door  10  to jamb  16 . As illustrated, hinge  26  is a conventional pin-type hinge. However, those skilled in the art will recognize various alternative types of hinges may be employed. As shown best in FIG. 2A, outer face  18 B, which indicates the inside of the door, closes against or nearly against firestop  24 . 
     Referring now to FIG. 3, horizontal header  14  is illustrated with firestop  24 A coupled to header  14 . Firestop  24 A is coupled to header  14  with a screw or other type of fastener  28 . Firestop  24 A has a channel  30  defined therein. Channel  30 , as illustrated, is G-shaped and has an at least partially open wall  32 . As illustrated, wall  32  extends only about half the thickness of firestop  24 A. In addition to partially open wall  32 , firestop  24 A has a horizontal wall  34  extending in a plane parallel to horizontal header  14 . A vertical wall  36  extends between horizontal wall  34  and a second horizontal wall  38  positioned adjacent or against header  14 . A partial vertical wall  40  extending into channel  30  may be used to help secure and guide a slider therein as will be further described below. 
     Firestop  24 A may have a mounting portion  42  adjacent to channel portion  30 . Screw  28  may be mounted through mounting portion  42 . 
     Partially open wall  32  may include a weatherstrip channel  44  having a weatherstrip  46  therein. Weatherstrip  46  closes any gap between door  10  and firestop  24 A. 
     Referring now to FIG. 4, the relative position of door  10  and firestop  24 A is illustrated. Door  10  preferably has a closer  50  positioned between outer faces  18 A and  18 B. This configuration provides an aesthetically pleasing door in which assembly is only minimally visible. 
     Closer assembly  50  includes a biasing element  52  that has a pivot axis  54  extending therefrom. Pivot axis  54  may have a bushing  56  positioned thereon. Closer assembly  50  also includes an arm  58  having a first end  58 A and a second end  58 B. First end  58 A is coupled to bushing  56  so that arm  58  rotates therearound. Arm  58  is illustrated as a dash line for simplicity purposes and will be further illustrated below. The pivot axis  56  remains stationary relative to the door. The unit thus has a restoring force to close the door caused by the internal mechanism of the biasing element  52  about the pivot axis  56 . 
     A slider  60  is positioned within firestop  24 A. Slider  60  slides within channel  30  as the door moves from a closed position to an open position and back again. Slider  60  has an arm retainer  62  that is used to rotatably couple to second end  58 B of arm  58 . 
     Referring now to FIGS. 5A,  5 B, and  5 C, respective front, side and top views of slider  60  are illustrated. As mentioned above, slider  60  has arm retainer  62  extending from a main body  64 . With respect to the relative position of the door, retainer  62  extends upward from main body  64 . A retainer arm  66  also extends in upward direction from main body  64 . Retainer arm  66  in conjunction with wall  40  help retain slider  60  within channel  30 . Preferably, slider  60  is made from a resilient material such as plastic, Delrin® or nylon. Channel  30  may also include a lubricant (not illustrated) to assist in the smooth operation of slider  60 . 
     Preferably, arm  58  is placed over arm retainer  62  without the use of fasteners. Of course, as will be further described below, fasteners may be used to secure arm  58  to slider  60  depending on the geometric configuration. 
     Referring now to FIG. 6, another embodiment illustrates arm  58  coupled to slider  60 ′ through the use of a fastener  70 . As can be seen, retainer  62 , arm  58 , and pivot bushing  56  lie on a substantially horizontal pg, 10  plane. Also, the top edge  72  of door  10  also lies in the same substantially horizontal plane. To phrase it in another way, the thickness T of firestop  24 A if extended over to the door includes slider  60 , arm  58 , bushing  56 , and top portion of door  72 . That is, slider  60 , arm  58 , bushing  56 , and top portion of door  72  extend only a predetermined distance below the header  14  which corresponds to thickness T. Arm  58  in this embodiment is not entirely horizontal and thus has a slight elbow  74  to avoid partial wall  32 . 
     Referring now to FIG. 7, a door  10  is illustrated in a closed position and a partially open position (in dashed lines). As can be seen, bushing  56  remains fixed within door  10  while being rotatably coupled to arm  58 . Simultaneously, slider  60  moves within channel  30  as toward hinge  26 . As is illustrated, in a closed position, slider  60  is in the leftmost position while in a partially open position slider  60  moves to the right within channel  30 . The biasing element  50  provides a biasing effort to close the door as is known to those skilled in the art. 
     Arm  58  is illustrated having a slight angular or “dog-leg” configuration. 
     Referring now to FIG. 7A, arm  58  may also have a straight arm  58 ′ depending on the geometry of the closer, door and door opening. 
     Referring now to FIG. 8, a closer assembly  50 ′ may be coupled outside door  10 . That is, door closer assembly  50 ′ may be coupled to the push side door face  18 A or  18 B. In the exterior mounted configurations, slider  60  still slides within a similar firestop channel  30  as described above. 
     Referring now to FIG. 9, header  14  is illustrated with an alternative cross section of a firestop  24 A. In this embodiment, firestop  24 A′ is generally C-shaped and has a modified slider  60 ′ positioned therein. Horizontal wall  34 ′ has an opening  80  therein so that a fastener  82  may be used to secure firestop  24 ′ to horizontal header  14 . Slider  60 ′ has a groove  84  to prevent interference between slider  60 ′ and fastener  82 . A pin  86  may be used to couple arm  88  to slider  60 ′. 
     Referring now to FIG. 10, an embodiment similar to that of FIG. 9 is illustrated. Therefore, the same reference numerals are used to indicate the same components. The firestop  24 A′ and slider  60 ′ are the same as FIG.  9 . However, the firestop  24 A′ could also have other configurations such as those shown in FIGS. 3-5C. In this embodiment, horizontal header  14 ′ has been modified from that shown in the above figures. This embodiment is particularly useful for a pre-existing door frame. That is, the door frame  14 ′ is referred to in the industry as a rabbetted header that includes an integral firestop  90 . If, however, a door closer is desired to be employed according to the present invention, firestop  24 A′ is coupled to header  14 ′ on the previous firestop  90 . To align firestop  24 A′ with door  10 , door  10  is shortened in height. To provide a more finished surface, a filler  92  may be positioned on header  14 ′ to conceal that the door length has been reduced. 
     In operation, it is preferred that the door and door closer assembly are assembled in a factory environment rather than on the jobsite. However, the present invention applies to either situation. The conventional firestop of a door is replaced with a firestop configured according to the present invention having a channel  30  therein. The channel  30  allows the slide to move therein in a nearly concealed and aesthetically pleasing manner. In a retrofit configuration such as that described in FIG. 10 above, a new firestop is coupled to the door frame. The firestop has an at least partially open side so that the arm with the slider in channel  30  may move therein. The closer is mounted so that a biasing force on the arm allows the door to move to a closed position when opened. 
     When the present invention is used in a pre-existing door environment, the new firestop track with open channel  30  is coupled to the existing header. The door is then reduced in height and a closer assembly is coupled to the door. The slider assembly may be coupled externally or between the door panels. The slider is positioned within the channel which in turn is coupled to the closer arm for operation. 
     Advantageously, the present invention may be configured in a factory environment to allow testing and alignment of the door closer and door within the frame. This is one less operation that the trades are required to perform and therefore the overall cost of the installation of the door within the opening is reduced. 
     While particular embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Accordingly, it is intended that the invention be limited only in terms of the appended claims.

Technology Classification (CPC): 8