Abstract:
A system for supporting a door frame, and in particular a metal door frame, during build-up of a wall about the door frame. Vertical alignment devices allow for placement of the door frame in a plumb configuration with respect to the floor and allows for fine adjustment through use of turnbuckle devices. A horizontal spreader device, also having longitudinal adjustment, provides lateral support to the door frame to reduce inward bowing of the sides of the door frame towards one another during build-up of the wall. Also, a header support device serves to maintain a parallel relationship between the header of the door frame and the threshold by compensating for sagging in the header, and also uses a longitudinal adjustment device.

Description:
BACKGROUND OF THE INVENTION 
   This invention relates generally to a system for supporting a door frame during the installation or modification thereof. 
   In constructing a building, one typical means for holding a metal door frame stationary involves the precise cutting of lengths of wood, which are attached to the door frame in a manner to hold the door frame vertical. In this arrangement, the wood members must be precisely cut, and often times the wood members, having already been cut, are thrown away after use, which is wasteful. It may take two workers upwards of 45 minutes to brace the door in this manner. 
   Another problem arising is maintaining the sides of the door frame parallel to one another, and the header of the door frame straight, during laying of masonry against the door frame. If not properly supported, the sides of the door frame may bow inwardly, and the header may sag, due to the pressure of the masonry. 
   SUMMARY OF THE INVENTION 
   Generally, the present invention includes devices for vertically aligning a door frame, maintaining the sides of a door frame parallel to one another, and maintaining the header of the door frame parallel with the door frame threshold. 
   The vertical alignment device includes an elongated portion having a first end and a second end, and a foot pivotally connected to the first end of the elongated portion for rigidly attaching the elongated portion to a surface, such as a floor, wall, footer, the ground, etc. A grip is pivotally attached to the second elongated portion and is configured for slidably engaging with the door frame. 
   The header support device includes an elongated portion with first and second ends, a first engagement member being connected to the first end and configured for engaging the threshold. A collar is attached to the second end of the elongated portion, and a second engagement member, which engages the door frame header is attached to the collar. The collar is rotatably connected to the second end of the elongated portion and includes a threaded bore therein for allowing selective adjustment between the first and second engagement members. 
   The horizontal spreader device includes an elongated portion with first and second ends, with the first engagement member being connected to the elongated portion for engaging a side of the door frame. A second engagement member is also provided for contacting the opposite door frame. Interposed between the second end of the elongated portion and the second engagement member is a collar device such as used in connection with the header support, for allowing the distance between the first and second engagement members to be selectively adjusted. 
   The present invention also includes methods of installing and adjusting each of the vertical alignment, horizontal spreader, and header support devices. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing, as well as other objects of the present invention, will be further apparent from the following detailed description of the preferred embodiment of the invention, when taken together with the accompanying specification and the drawings, in which: 
       FIG. 1  is a perspective view of a typical door frame used in building construction; 
       FIG. 2A  is a perspective view of vertical alignment devices of the door frame support system of the present invention in use supporting the door frame shown in  FIG. 1 ; 
       FIG. 2B  is a perspective view of a horizontal spreader device of the door frame support system constructed in accordance with the present invention maintaining vertical alignment of the sides of a door frame; 
       FIG. 2C  is a perspective view of a header support device of the door frame support system constructed in accordance with the present invention supporting the header of a door frame; 
       FIG. 3A  is a side elevational view of a vertical alignment device constructed in accordance with the present invention; 
       FIG. 3B  is an exploded view of the vertical alignment device shown in  FIG. 3A ; 
       FIG. 4A  is a side elevational view of a horizontal spreader/header support device constructed in accordance with the present invention; and 
       FIG. 4B  is an exploded view of the horizontal spreader/header support device shown in  FIG. 4A . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The accompanying drawings and the description which follows set forth this invention in its preferred embodiment. However, it is contemplated that persons generally familiar with building construction and door frame installation and modification will be able to apply the novel characteristics of the structures illustrated and described herein in other contexts by modification of certain details. Accordingly, the drawings and description are not to be taken as restrictive on the scope of this invention, but are to be understood as broad and general teachings. 
   Referring now to the drawings in detail, wherein like reference characters represent like elements or features throughout the various views, the door frame support system of the present invention is indicated generally in the figures by reference character  10 . 
     FIG. 1  illustrates a conventional door frame, generally D, having vertically extending side portions, S, and a header portion H bridging across and connected to the upper portion of side portions S. A masonry wall, generally W, is illustrated in  FIG. 1  built up about the side portions S of door frame D. As shown by phantom lines  14 , side portions S may, during installation of the masonry wall W, bow inwardly if not otherwise restrained against such movement. The bowing-in of sides S of door frame D during laying of the block wall W occurs in part because of the pressure exerted on sides S by the brick or blocks B, and mortar M used in forming the masonry wall. Door frame D also includes a door stop portion  16  extending along sides S and header H. 
   When a door frame D is installed, the objective is to maintain the side portions S in a vertical, parallel relationship with respect to one another, and for the header portion H to be in a horizontal, parallel relationship with respect to the threshold, generally T, adjacent to or forming a part of the floor surface, generally F. These parallel relationships ensure that a door (not shown) installed in the door frame D will open and close freely without binding on the sides S or header portion H of the door frame. 
   Turning to  FIG. 2A , vertical alignment devices, generally  20 , are shown, and such devices  20  form a part of door frame system  10  of the present invention. Vertical alignment devices  20  include a foot portion, generally  22 , an elongated portion, generally  24 , and a grip portion, generally  26 . Foot portion  22  includes a bracket  28  having a flange  30 . Bracket  28  defines an opening  34  through which a fastener  36 , such as a nail, screw, spike, or other device can be driven for rigidly attaching the bracket to surface F. For example, if surface F is concrete, a Hilti device or TapCon fasteners may be used. For other surfaces, such means could be used, or, conventional nails, screws, bolts, the like could also be used. 
   Elongated portion  24  includes two struts  40 ,  42 . Strut  40  is connected to foot  22 , and strut  42  is connected to grip  26 . Connected in between struts  40  and  42  is a turnbuckle device, generally  46 , which allows the overall length of elongated portion  24  to be selectively varied. By varying the overall length of elongated portion  24 , the distance between foot  22  and grip  26  can also be varied for use in vertically aligning and maintaining such vertical alignment in door frame D. 
   Through use of a vertical alignment device  20  on each side S of door frame D, the door frame may be maintained in vertical alignment across its width during construction, as a masonry wall, wood or metal studded wall, stone wall, or other type of wall is constructed around the door frame. 
   Turning to  FIGS. 3A and 3B , vertical alignment devices  20  is shown in more detail. Struts  40  and  42  each have a threaded end  48  which is received by a respective sleeve  50  connected to foot  22  and grip  26 . Grip  26  includes an interior profile, or channel  52 , for engaging a portion of the door frame, preferably a door frame edge, or flange, E for engaging and maintaining the door frame in a vertically aligned position. Channel  52  is configured for receipt of the door frame flange E. Resilient members  54  can be provided in channel  52  to reduce scratching, marring, or other damage to the door frame during use. 
   A locking device, generally  56 , such as a screw or bolt  58  can be used for selectively locking grip with respect to door frame D. Channel  52  of grip  26  allows for sliding movement of grip along flange E of door frame D. Once grip  26  is in the proper position, engaging flange E, grip is locked to flange E, and hence to door frame D by turning the enlarged head portion  60  of bolt  58  such that bolt  58  engages and fixes grip  26  to door frame D. 
   As shown in  FIG. 3B , a collar  62  is threadingly connected to the end of each strut  40 ,  42  opposite sleeves  50 . Collars  62  include a threaded bore  64  for receipt of end  66  of struts  40 ,  42  and also define a second threaded bore  68  for receipt of a threaded rod  70  of turnbuckle member  74 . Turnbuckle member  74  includes threaded rod portions  70 ,  72 , each being threaded in the opposite direction, such that as turnbuckle member  74  is rotated in a first direction, struts  40 ,  42  are moved outwardly with respect to each other. When turnbuckle member  74  is rotated in the other direction, struts  40 ,  42  are drawn towards one another. Turnbuckle member  74  includes an elongated hexagonal-cross section portion  76  which may be engaged by an ordinary wrench, and also includes two outwardly extending handles  78  which can be engaged by hand in order to rotate turnbuckle member  74 . Jam nuts  80  are provided on threaded rods  70 ,  72  in order to fix rotation of threaded rods  70 ,  72  with respect to the collar  62  in which they are received. 
   Turning to  FIG. 2B , a horizontal spreader device, generally  90 , is shown, which is part of door frame system  10 . Horizontal spreader device  90  includes an elongated portion, generally  92 , having two engagement members  94 ,  96  for engaging side portions S of door frame D. Elongated portion  92  includes a collar device, generally  98 , connected to adjustable engagement member  96  (adjustment member  94  is relatively stationary) for varying the distance between engagement members  94 ,  96 . Horizontal spreader  90  may be used when wall portions, and particularly masonry wall portions, are built up around door frame D, and serve to reduce inward bowing of door frame sides S, as discussed above, during such wall construction. 
     FIG. 2C  illustrates a header support device, generally  100 , of door frame support system  10 , which is used to reduce sagging or other misalignment of header H of door frame D during construction of a wall surrounding door frame D. Header support device  100 , similarly to horizontal spreader  90 , discussed above, also includes an elongated portion  92  with a collar device  98 . One end of collar device  98  is connected to a generally stationary engagement member  96 , and the one end of the elongated portion includes an engagement member  94 . Preferably, collar device  98  is positioned against engagement member  96  such that it is convenient for use when the wall portion is built above the header. For example, if a mason is laying a masonry wall above header H, the mason will be able to readily compensates for sagging of the header simply by adjusting collar device  98  to effectively increase the distance between engagement member  96  and engagement member  94 , thereby effectively increasing the overall length of elongated portion  92 . 
   Turning to  FIGS. 4A and 4B , a more detailed construction of horizontal spreader device  90  and header support device  100  are illustrated. As noted above, horizontal spreader device  90  and header support device  100  differ from one another, primarily, only in the overall length of elongated portions  92 . 
   Collar device  98  used on horizontal spreader  90  and threshold support  100  includes a first bore  102  which receives the end of a strut  104 . Strut  104  is essentially a tube which at one end includes a bore  106  for receipt of a post  108  connected to engagement member  94 , and at the other end is received in bore  102  of sleeve  112  of collar device  98 . Sleeve  112  may rotate freely with respect to strut  104 . Sleeve  112  also includes a threaded bore  114  for receipt of threaded rod  116 , which is fixedly attached to engagement member  96 . When assembled, rotation of sleeve  112 , which can be done by grasping and turning of outstanding handles  118  connected to sleeve  112 , allows for the distance between engagement members  94  and  96  to selectively be varied. This is accomplished through the threaded engagement of rod  116  with threaded bore  114  of sleeve  112 . 
     FIGS. 2B and 2C  illustrate different devices of door frame system  10  being used simultaneously. For example,  FIG. 2  illustrates vertical alignment devices  20  being used simultaneously with horizontal spreader device  90 . This combination device would be appropriate when a wall is being built up along the sides of door frame D.  FIG. 2C , which includes the vertical alignment devices  20  and header support device  100 , would be appropriate when the wall is being built on top of header H of door frame D. It is to be understood, however, that other combinations of devices  20 ,  90 , and  100  could be used as desired, and as necessary, and the present invention is not to be limited simply to the combinations illustrated in  FIGS. 2A through 2C . Specifically, each of the devices  20 ,  90 ,  100  could be used singularly, and not in combination with any of the other two devices, depending on the circumstances. 
   A method of using door frame system  10  could involve fastening door frame D to floor surface F and using a level  120  ( FIG. 2A ) to ensure that the door frame is plumb with respect to the floor surface. Grip  26  is used to engage a flange E of door frame D and bolt  68  is tightened to fix grip  26  with respect to door frame D. Foot  22  is secured to the floor surface using a fastener. Using level  120 , and preferably with two vertical alignment devices  20  in place, as shown in  FIGS. 2A through 2C , door frame D is set plumb by adjustment of turnbuckle devices  46 . 
   A method of using horizontal spreader device  90  could involve placing stationary engagement member  94  against either side S of door frame D and then placing adjustable engagement member  96  against the opposite side S. Horizontal spreader device  90  is adjusted and maintained in place by rotating the collar device  98  such that engagement portions  94  and  96  press outwardly on sides S of door frame D with sufficient force to support horizontal spreader device  90  in place, and also to maintain sides S of door frame D in a plumb relationship. 
   A method of using header support device  100  is similar to that discussed above with respect to horizontal spreader device  90 . Stationary engagement member  94  could be positioned against threshold T, and the adjustable engagement member  96  positioned adjacent header H of door frame D, to allow easy access during build-up of a wall above header H. Accordingly, in the event header H begins to sag, such can be readily compensated for by rotation of collar device  98 . 
   Devices  20 ,  90 , and  100  are preferably constructed of steel, although aluminum or other suitable materials could be used. Portions of the devices could be welded or cast, or, if a plastic or polymer material is used, injection molded. 
   While preferred embodiments of the invention have been described using specific terms, such description is for present illustrative purposes only, and it is to be understood that changes and variations to such embodiments, including but not limited to the substitution of equivalent features or parts, and the reversal of various features thereof, may be practiced by those of ordinary skill in the art without departing from the spirit or scope of the following claims.