Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to Provisional U.S. Patent Application Serial No. 60/242,677, filed on Oct. 24, 2000. 
    
    
     FIELD OF THE INVENTION 
     The invention is directed to a clad frame system for doors, particular for exterior doors. Specifically, the invention is directed to a frame system having two side jambs, a header, two side brickmolds and a header brickmold, each of which is covered by a one-piece, galvanized steel, rolled cladding. 
     BACKGROUND 
     The selection of a suitable door frame for installation in an exterior door opening presents a wide variety of demands to the builder. It is important that door frames present a pleasing appearance without being cost prohibitive. They also need to have strength sufficient to hang a door. Another desirable property is a hardness sufficient to resist damage, such as by scuffing, denting or scratching. Many known door frames are unsuitable, because they fail to provide for all of these properties to the satisfaction of builders. 
     A typical door frame includes three members: two side jambs and one header extending between the jambs. Typically, a threshold is provided at the bottom of the frame. Many such door frames are made of wood. However, wood suffers from the disadvantage of succumbing to wood rot. Wood rot in door frames is known and is described in greater detail in U.S. Pat. No. 6,161,343. Generally speaking, when the moisture content rises above about 25% in wooden portions of the door frame, wood rot begins. The water is absorbed by the wood usually through an exposed end grain exposed to water. Once wood rot takes hold, the strength of the frame becomes markedly decreased, requiring removal of the rotten portions. Because replacement or repair due to wood rot is inevitable with wooden door frames, door frame manufacturers are unable to confidently guarantee customer satisfaction for an extended period of time for their door frames. 
     Often, wooden door frames are formed of high-grade lumber (wood planks having a relatively unflawed wood grain pattern on visible surfaces). While high-grade lumber presents an aesthetically pleasing appearance, it is often relatively expensive. One attempt to lower the overall cost involves the substitution of inferior grades of wood for the finished lumber. However, flaws found in inferior grades of wood, such as discontinuities in the surface, may not provide an appearance satisfactory to many homebuyers. 
     Wooden door frames also suffer from the disadvantage of not having a hardness sufficient to resist scuffing, scratching, denting, or the like. Attempt to solve this problem involve substitution of the wood with materials having a greater hardness. While these materials may have the requisite hardness, they often do not have a satisfactory combination of strength and relatively low cost. 
     Other attempts to solve the wood rot problem involve the use of several claddings that fit together to cover at least the front surface and side surface of each of the side jambs and the header. However, these cladding pieces require multiple molds, extrusion tools, or the like, in order to manufacture a full cladding set that will cover the desired surfaces of each of the door frame members. This approach also suffers from the disadvantage of being relatively complicated to assemble and install. 
     Thus, those skilled in the art will recognize that there is a need in the art for a door frame that need not be replaced due to wood rot, so that a door frame manufacturer may guarantee a buyer&#39;s satisfaction over an extended period of time. It is also apparent to those skilled in the art that there is a need for a door frame that offers more resistance to damage, such as by scuffing, scratching and denting, than is offered by wood door frames. It is likewise apparent to those skilled in the art that there is a need for such a door frame that is also relatively inexpensive. 
     BRIEF SUMMARY OF THE INVENTION 
     The inventor has discovered that these needs may be met by a door frame system that protects exterior surfaces of door frame members from the elements. The door frame system comprises first, second and third frame members and first, second and third elongate cladding strips. The first frame member includes a left side jamb and a left brickmold extending therealong. The second frame member includes a right side jamb and a right brickmold extending therealong. The third frame member includes a header and an upper brickmold extending therealong. The first and second frame members extend orthogonally from opposite ends of the third frame member to define a door opening having an exterior side. The first and second side jambs and the header each have a door stop jamb surface, a jamb surface facing toward the exterior side, and a jamb surface facing toward the door opening. Each of the brickmolds has a first brickmold surface facing toward the door opening, a second brickmold surface facing away from the door opening, and a third brickmold surface facing toward the exterior side. The first, second and third elongate cladding strips frictionally engage the first, second and third frame members, respectively. Each of the elongate cladding strips includes an inner flange connected to an outer flange. The inner flange engages one of the first and second side jambs and side header and includes a first leg, a second leg and a body portion from which the first and second inner flange legs extend. The first inner flange leg at least partly engages a respective one of the jamb surfaces facing the exterior side. The second inner flange leg engages most of a surface area of a respective one of the doorstop jamb surfaces. The body portion at least partly engages a respective one of the jamb surfaces facing the door opening. Each of said elongate cladding strips also includes an outer flange connected to the inner flange. The outer flange engages a respective one of the brickmolds and includes first and second legs and a decorative portion from which the first and second outer flange legs extend. The first outer flange leg engages a respective one of the first brickmold surfaces. The second outer flange leg engages a respective one of the second brickmold surfaces. The decorative portion engages a respective one of the third brickmold surfaces. Each of said elongate cladding strips is made of metal and is retained upon a respective one of the frame members. 
     Another embodiment of the invention is a one-piece cladding strip for extending along and protecting surfaces of one of first, second and third frame members defining a door opening. The first frame member has a first side jamb and a first brickmold extending along the first side jamb. The second frame member has a second side jamb and a second brickmold extending along the second side jamb. The third frame member has a header and a header brickmold extending along the header. Each of the side jambs and the header has a first frame surface facing an exterior side of the door opening, a second frame surface providing a door stop and facing an interior side of the door opening, and a third frame surface facing the door opening. Each of the brickmolds includes a first brickmold surface facing the door opening, a second brickmold surface facing away from the door opening, and a third brickmold surface facing the exterior side of the door opening. The one-piece cladding strip comprises inner and outer flanges. The inner flange has a first leg at least partly engaging the first frame surface, a second leg engaging most of a surface area of the second frame surface, and a body portion at least partly engaging the third frame surface. The first inner flange leg is orthogonally joined to the body portion. The body portion is orthogonally joined to the second inner flange leg. The first and second inner flange legs are oriented parallel to one another. The outer flange has a first leg engaging the first brickmold surface, a second leg engaging the second brickmold surface and a decorative portion engaging the third brickmold surface. The first outer flange leg is orthogonally joined to the decorative portion. The decorative portion is orthogonally joined to the second outer flange leg. The first and second outer flange legs are oriented parallel to one another. The first inner flange leg is joined orthogonally to said first outer flange leg. The cladding strip is elastically deformable such that said cladding strip may be snapped into position upon one of the frame members for frictional engagement therewith, and is made of metal. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the clad frame system of the invention. 
     FIG. 2 is a perspective view of first, second and third frame members of the clad frame system with the cladding strips removed. 
     FIG. 3 is a cross-sectional view of FIG. 1 taken along the line A—A and further includes a fragmentary portion of a wall. 
     FIG. 4 is a perspective view of the clad frame system of the invention in combination with a steel entry door. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As illustrated in FIGS. 1,  2  and  3 , the clad frame system  1  of the present invention includes first and second upright frame members  4 ,  7  that are spaced and parallel to each other. The frame system also includes a header frame member  10  extending between topmost portions  11 ,  12  of the upright frame members  4 ,  7 . It may be noted that each of the frame members  4 ,  7 ,  10  is elongate. Together, the upright frame members  4 ,  7  and header frame member  10  define a door opening  13 . With reference to axes x, y and z, the door opening  13  separates an exterior side  16  (in foreground) of opening  13  from an interior side  19  (background) of opening  13 . Preferably, the frame system  1  is used for framing a door on the exterior of a building. Thus, exterior side  16  is disposed outside the building. Consequently, interior side  19  is disposed inside the building. 
     As best illustrated in FIGS. 2 and 3, each of the frame members  4 ,  7 ,  10  preferably includes at least two subcomponents: a jamb and a brickmold. Thus, the first upright frame member  4  includes a left side jamb  28  and a left brickmold  31  extending therealong. The second upright frame member  7  correspondingly includes a right side jamb  34  and a right brickmold  37  extending therealong. Right side jamb  34  is adjacent a masonry wall  38  and a portion of right side jamb  34  projects inward (toward the interior of the door opening  13 ) from wall  38  and extends to a back surface  39 . Similar to the left and right side jambs  28 ,  34  and left and right brickmolds  31 ,  37 , an upper brickmold  43  extends along a header jamb  40 . Together, upper brickmold  43  and header jamb  40  comprise the header frame member  10 . In each case, brickmolds  31 ,  37 ,  43  extend along a surface of the jambs  28 ,  34 , and  40  that faces exterior side  16 . Preferably, the brickmolds  31 ,  37 ,  43  cover most of an area of this surface. The term “most” as used herein is defined as 50% or greater. As shown in FIG. 2, brickmolds  31  and  43  meet at a 45° mitered joint  22 , whereas brickmolds  37  and  43  meet at a 45° mitered joint  25 . It is understood that other angles for the mitered joint  25  may be used. 
     As best illustrated in FIGS. 1 and 3, the frame system  1  also includes first, second and third cladding strips  46 ,  49 ,  52  at least partially covering each of frame members  4 ,  7 ,  10 , respectively. Similar to frame members  4 ,  7 ,  10 , cladding strips  46 ,  49 ,  52  are elongate and meet at 45° mitered joints  22 ,  25 . Although not essential to the invention, the frame system  1  may also include a threshold  55  extending between bottom most portions  58 ,  61  of first and second frame members  4 ,  7 . 
     FIG. 3 illustrates a cross-section of the second upright frame member  7  (including right side jamb  34  and right brickmold  37 ) and second cladding strip  49 . While similar cross-sections of the first upright frame member  4  and upper frame member  10  are not depicted, it is understood that they (and the corresponding jambs  28 ,  40  and brickmolds  31 ,  43 ) have the same configuration in cross-section. As seen in FIG. 3, second cladding strip  49  frictionally engages second upright frame member  7 . Second cladding strip  49  includes an inner flange  60  and an outer flange  80 , each of which is generally U-shaped in cross-section. While inner flange  60  extends along and at least partially overlies some of right side jamb  34 , outer flange  80  extends along and at least partially overlies some of right brickmold  37 . 
     Inner flange  60  has first and second legs  62 ,  64  that are spaced apart from each other. Preferably, first and second legs  62 ,  64  are generally parallel to one another. Inner flange  60  also has a body portion  66  that connects to, and extends between, legs  62 ,  64  at edges  63 ,  65 , respectively. Preferably, body portion  66  is oriented about 90° relative to legs  62 ,  64 . First leg  62  extends along right side jamb  34  adjacent the portion of a surface  68  that faces toward exterior side  16  but which is not covered by right brickmold  37 . Body portion  66  extends along right side jamb  34  adjacent the portion of a surface  72  that faces the door opening  13 . Second leg  64  extends along right side jamb  34  adjacent doorstop jamb surface  70 . 
     Although not essential to the invention, weather stripping may be used to provide a barrier to the elements in between the door on one hand and the doorstop jamb surface  70  and second leg  64  on the other hand. If so, the weather stripping should be disposed at least partially within kerf  74  and project inwardly towards interior side  19 . The weather stripping should also project along doorstop jamb surface  70  towards door opening  13  up to second leg  64 . That way, the doorstop jamb surface  70  is substantially protected from exposure to the elements. 
     Preferably, second leg  64  extends along most of doorstop jamb surface  70 . That way, a relatively wide variety of configurations of weather stripping may be utilized. On the other hand, if second leg  64  did not extend along most of door stop jamb surface  70 , the weather stripping would need to be especially configured to project toward door opening  13  along door stop jamb surface  70  up to second leg  64 . Otherwise, doorstop jamb surface  70  would remain unprotected from the elements. When the length of second leg  64  is selected such that it extends along most of doorstop jamb surface  70 , the weather stripping need not be especially configured to have such a projection. A second leg  64  that extends along most of doorstop jamb surface  70  provides an additional advantage. Such a longer second leg  64  grips second upright frame member  7  with greater frictional engagement than compared to a shorter second leg  64 . 
     Outer flange  80  has first and second legs  82 ,  84  that are spaced apart from each other. Preferably, first and second legs  82 ,  84  are generally parallel one another. Outer flange  80  also has a decorative portion  86  that connects to, and extends between, legs  82 ,  84  at edges  83 ,  85 , respectively. Preferably, decorative portion  86  is generally oriented about 90° relative to legs  82 ,  84 . 
     First leg  82  extends along right side brickmold  37  adjacent the portion of a surface  88  that faces the door opening  13  but which is not covered by right brickmold  37 . Second leg  84  extends along right brickmold  37  adjacent the portion of a surface  90  that faces away from the door opening  13 . Preferably, second leg  84  completely covers surface  90 . While FIG. 3 depicts an end  91  of second leg  84  as abutting masonry wall  38 , it is understood that other lengths of second leg  84  may be selected that may not abut wall  38 . Similarly, it is understood that clad frame system  1  may be used with thicker or thinner walls  38 . 
     Decorative portion  86  extends along right brickmold  37  adjacent the surface  92  that faces toward exterior side  16 . While decorative portion  86  is illustrated as having two stepped segments  87 , it is understood that any other configuration may be utilized. For example, decorative portion  86  may be configured to simulate decoratively carved brickmolds used with door frames. Preferably a decorative pattern, such as a wood grain pattern, is rolled into the decorative portion  86 . 
     The lengths of first and second legs  82 ,  84  and decorative portion  86  may be widely varied to provide whatever appearance is desired and/or to suit the particular dimensions of right side jamb  34  and right brickmold  37 . For example, while first and second legs  82 ,  84  of outer flange  80  are depicted as extending forwardly beyond edges  94 ,  96 , leaving a gap  98 , the lengths of first and second legs  82 ,  84  may be shortened to allow a snug engagement between decorative portion  86  and surface  92 . Similarly, the lengths of legs  82 ,  84  may be modified to allow any other size gap  98  or to allow another decorative pattern instead of stepped segments  87 . Preferably, a support  99  is secured to brickmold  37 , as best shown in FIG.  3 . Support  99  is positioned at the edge of brickmold  37  along edge  96  and extends the length thereof. Support  99  may be formed of wood or a wood composite and may be adhesively secured to brickmold  37 , such as with polyvinyl acetate. Alternatively, support  99  may be formed integral with brickmold  37 . The support  99  fills the gap  98 , and thereby resists crushing or deformation of decorative portion  86 . 
     It is understood that the configurations of the first, second and third cladding strips  46 ,  49 ,  52  are identical, except for their lengths (third cladding strip  52  is shorter than the first and second cladding strips  46 ,  49  in a typical doorway that is taller than it is wide). Consequently, cross-sections of the left side jamb  28 , left brickmold  31 , header jamb  40 , upper brickmold  43 , and first and third cladding strips  46 ,  52  are identical to those of the right side jamb  31 , right brickmold  34  and second cladding strip  49 , respectively. 
     The inventor has also discovered that the wood rot problem may be avoided if the proper material is selected for the cladding strips  46 ,  49 ,  52 . For example, when the cladding strips  46 ,  49 ,  52  are made of a relatively rigid material, the cladding strips  46 ,  49 ,  52  provide the strength sufficient to hold the inventive frame system up even if wood rot degrades the structural integrity of frame members  4 ,  7 ,  10  when they are made of wood. Preferably, the material for the cladding strips  46 ,  49 ,  52  is steel, more preferably hot dip galvanized steel, even more preferably hot dip galvanized 26 GA sheet steel. Preferably, the cladding strips  46 ,  49 ,  52  are also at least somewhat elastically deformable such that they may be snapped into place on the frame members  4 ,  7 ,  10  for frictional engagement therewith. The cladding strips  46 ,  49 ,  52  may also be provided with a protective layer on exteriorly disposed surfaces, i.e., those that are exposed to the elements. Such a protective layer includes paint. 
     The cladding strips  46 ,  49 ,  52  are preferably roll formed, i.e., one piece of cladding stock material is rolled between rollers to achieve the desired configuration of cladding strips  46 ,  49 ,  52 . When such a method is employed, a one-piece cladding is thus produced from a one-piece stock material, i.e., so-called unitarily forming. Roll forming may be contrasted with other methods of producing cladding, such as joining two or more components to achieve the final configuration of the cladding. Such other methods do not result in a unitarily formed one-piece cladding. 
     The jambs  28 ,  34 ,  40  and brickmolds  31 ,  37 ,  43  may be made of wood. Because a cladding conceals portions of the jambs  28 ,  34 ,  40  and brickmolds  31 ,  37 ,  43 , a relatively inferior grade of wood is preferred from a cost standpoint. The threshold  55  may be made of any material known in the art for such a use. 
     The clad frame system  1  may be assembled as follows. One end of each of the right and left brickmolds  31 ,  37  and first and second cladding strips  46 ,  49  are cut at a 45° angle for later forming of mitered joints  22 ,  25  with the upper brickmold  43  and third cladding strip  52 , respectively. Thus, each of the ends of the upper brickmold  43  and third cladding strip  52  is also cut at a 45° angle, thus completing the configuration necessary for the mitered joints  22 ,  25 . Next, the side jambs  28 ,  34  are parallel spaced and the header jamb  40  is laid at a right angle extending between the jambs  28 ,  34  and one end thereof. The threshold, if desired, is similarly laid between the opposite ends of the side jambs  28 ,  34 . The jambs  28 ,  34 ,  40  and threshold  55  are then nailed together at each of the four corners. The right, left and upper brickmolds  31 ,  37 ,  43  are then placed along surface  68  at a 90° angle relative the surface of the jambs  28 ,  34 ,  40  facing the exterior side  16  and placed against one another such that the cut corners form mitered joints  22 ,  25 . Thus placed, brickmolds  31 ,  37 ,  43  are then nailed or otherwise secured to the jambs  28 ,  34 , and  40  with brad nails. 
     The second cladding strip is then put in place as follows. The end  91  of the second leg  84  is placed rearward of edge  104  of right brickmold  37 . The cladding strip  49  is then pivoted around the right brickmold  37  and right side jamb  34  so that end  107  of the inner flange  60  is snapped into place over edge  110  of the right side jamb  34  and second leg  64  extends along door stop jamb surface  70  for frictional engagement therewith. Thus, cladding strip  49  is frictionally retained upon second frame member  7 . This method of installing the cladding is repeated for the first and third cladding strips  46 ,  52  along the first and third frame members  4 ,  7 , respectively, so that the first and third, and the second and third, cladding strips  46 ,  49 ,  52  meet at mitered joints  22 ,  25 , respectively. 
     As best shown in FIG. 4, a steel entry door D is supported by interior hinges (not shown) in well-known manner. Doorknob  200  or similar access member is provided to permit door D to be opened. Preferably, threshold  55  is disposed below door D. The door D and cladding strips are preferably manufactured from identical gauge galvanized steel. Because the cladding strips  46 ,  49 , and  52  are manufactured from the same material as is used to manufacture the door D, then paint color and texture differences are eliminated. The door D and the cladding strips  46 ,  49 , and  52  thus possess identical texture and gloss, presenting a more aesthetically pleasing appearance to the consumer. In the past, because the door was made from steel and the frame from wood, then those members would exhibit differences in both paint texture and gloss, sometimes to a marked extent. 
     Having thus described the invention, it will be realized that although the foregoing description of the inventor&#39;s preferred embodiment includes specific quantities, materials, dimensions and procedures, modifications and variations thereof might be employed without departing from the inventive concept herein.

Technology Category: 0