Door assembly

Patent metadata

Field	Value
Publication number	US-12037840-B2
Application number	US-202318120023-A
Country	US
Kind code	B2
Filing date	Mar 10, 2023
Priority date	Mar 3, 2017
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

A door assembly and a frame member for a door assembly. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a pair of side jambs. The invention may also be considered a frame member including a storage compartment. The frame member may include a core; and a top piece adjoining the core to form a structural member. The core and the top piece may be a composite of cellulosic material and at least one other material. The top piece may be a two-piece top piece and may include hollow cavities. Also disclosed are door jamb frame members and mullion frame members.

First claim

We claim:

1. A door frame member comprising:
a core having an interior side and an exterior side, opposite the interior side, the core defining an opening extending between the interior side and the exterior side and a channel in one of the interior side or the exterior side;
a base defining an excerpt, the base attached to the core such that the excerpt aligns with the opening; and
a removable cover removably attached to the base such that the base and the removable cover define one or more enclosed hollow cavities, the opening, the excerpt, the channel, and the one or more enclosed hollow cavities in communication with each other to define a storage compartment configured to house a door component, the storage compartment accessible by removing the removable cover from the base.

2. The door frame member according to claim 1 , further comprising a trim profile attached to the door frame member.

3. The door frame member according to claim 1 , wherein the core includes a lower portion formed of a decay resistant material.

4. The door frame member according to claim 1 , wherein the base and the removable cover are made of a composite of cellulosic material and at least one other material.

5. The door frame member according to claim 1 , wherein the base is attached to the exterior side, the core defining the channel in the interior side configured for the passage of component parts therethrough.

6. The door frame member according to claim 5 , wherein the core defines another opening therethrough such that the channel is in communication with the exterior side of the of the core.

7. The door frame member according to claim 6 , wherein the other opening is in communication with the one or more enclosed hollow cavities.

8. The door frame member according to claim 1 , wherein the excerpt forms a break in the base such that the base is discontinuous along a length of the door frame member.

9. The door frame member according to claim 1 , wherein the removable cover includes a stop portion and the base includes a rabbet portion, the rabbet portion is generally L-shaped and the stop portion is generally L-shaped, the stop portion overlapping the rabbet portion.

10. The door frame member according to claim 9 , wherein the base attaches to the core such that the rabbet portion wraps about an end of the core.

11. The door frame member according to claim 1 , wherein the base and the removable cover is made of a cellulosic-plastic composite.

12. The door frame member according to claim 11 , wherein an amount of cellulosic material in the cellulosic-plastic composite is between about 20 weight percent and about 70 weight percent of the weight of the cellulosic-plastic composite.

13. The door frame member according to claim 1 , wherein a thickness of the base and the removable cover attached to each other is between about 10% and about 50% of a total thickness of the door frame member.

14. The door frame member according to claim 1 , wherein the door frame member is a doorjamb.

15. The door frame member according to claim 1 , wherein the door frame member is a door mullion.

16. The door frame member according to claim 1 , wherein the removable cover and the base each include an outer leg, a mid leg, and an inner leg projecting therefrom, the outer leg of the removable cover mating with the outer leg of the base, the inner leg of the removable cover mating with the inner leg of the base, and the mid leg of the removable cover engaged with the mid leg of the base such that the removable cover is biased laterally relative to the base to secure the removable cover thereto.

17. A method for including component parts in a door assembly, the method comprising:
securing a base to a core such that an excerpt defined by the base is aligned with an opening defined by the core;
mating a removable cover with the base such that the removable cover and the base define at least one hollow cavity therebetween in communication with the opening, the base, the removable cover, and the core defining a compartment configured to house the component parts therein;
forming a channel in the core; and
forming at least one opening through the core in communication with the channel.

18. A door frame member comprising:
a core having a first side and a second side, opposite the first side, the core defining an opening extending between the first side and the second side and a channel in one of the first side or the second side; and
a top piece attached to the core to form the door frame member, the top piece comprising:
a base defining an excerpt, the base attached to the core such that the opening, the channel, and the excerpt are in communication with one another; and
a removable cover removably attached to the base, the top piece defining an enclosed hollow cavity between the base and the removable cover, the enclosed hollow cavity in communication with the excerpt, the channel, and the opening, the excerpt, the opening, the channel and the enclosed hollow cavity define a storage compartment configured to house a door component such that the door component is accessible by removal of the removable cover when the door frame member is installed in a door frame assembly.

19. A door frame assembly comprising:
a header;
a sill;
a first side jamb; and
a second side jamb, at least one of the header, the first side jamb, or the second side jamb being a door frame member according to claim 18 .

Assignees

• Endura Products Llc

Inventors

• Macdonald Kevin T
• Jaskiewicz Tomasz
• Johnson Eric

Classifications

• E06B2001/622

  especially adapted for door frames; Joint covering devices where the wall surface is parallel to the adjacent door or window frame part · CPC title

• E06B1/528

  with ducts for cables or pipes · CPC title

• E06B1/524

  Mullions; Transoms · CPC title

• E06B1/52

  Frames specially adapted for doors · CPC title

• E06B1/34

  Coverings, e.g. protecting against weather, for decorative purposes · CPC title