Protective door packaging for prehung door assemblies and method of packaging prehung door assemblies

Patent metadata

Field	Value
Publication number	US-12065299-B2
Application number	US-202218077408-A
Country	US
Kind code	B2
Filing date	Dec 8, 2022
Priority date	Dec 10, 2021
Publication date	Aug 20, 2024
Grant date	Aug 20, 2024

Abstract

A single unit protective door package for packaging of a single prehung door assembly. The door assembly comprises a door frame and a door slab pivotally attached to the door frame. The door frame includes right and left side jambs and a head jamb connecting upper ends of the right and left side jambs. The single unit protective door package comprises the door assembly, upper protective side caps each mounted to the door assembly at one of opposite upper corners of the door frame, lower protective side caps each mounted to the door assembly at one of lowermost edges of the door frame, and two support spacers each mounted to one of the lowermost edges of the door frame for elevating a bottom edge of the door slab above the ground to a distance compatible with a forklift, pallet jack or hand truck.

First claim

What is claimed is:

1. A single unit protective door package for packaging of a prehung door assembly, the single unit protective door package comprising:
a single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs;
a pair of upper protective side caps each mounted to the single prehung door assembly at one of opposite upper corners of the door frame;
a pair of lower protective side caps each mounted to the single prehung door assembly at one of lowermost edges of the door frame;
a pair of support spacers each mounted to one of the lowermost edges of the single prehung door assembly for elevating a bottom edge of the door slab above the ground; and
at least a first strap encircling the single prehung door assembly about at least one of the upper protective side caps or the lower protective side caps, wherein each of the support spacers includes a base member having a planar bottom surface adapted to engage a floor surface, and a planar top surface parallel to the planar bottom surface and configured to engage one of the lowermost edges of the door frame, and wherein each of the support spacers further includes a planar connecting member and at least one planar support member extending outwardly from the top surface, and wherein one of the right and left side jambs of the door frame is disposed between the least one planar support member and the connecting member of each of the support spacers.

2. The single unit protective door package as defined in claim 1 , wherein the door frame includes a door stop member fixed on at least the side jambs, and wherein each of the support spacers includes two support members spaced from one another a distance sufficient to receive the door stop member therebetween.

3. The single unit protective door package as defined in claim 1 , wherein each of the planar connecting member and the at least one planar support member are oriented to extend parallel to the associated jamb.

4. A single unit protective door package for packaging of a prehung door assembly, the single unit protective door package comprising:
a single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs;
a pair of upper protective side caps each mounted to the single prehung door assembly at one of opposite upper corners of the door frame;
a pair of lower protective side caps each mounted to the single prehung door assembly at one of lowermost edges of the door frame;
a pair of support spacers each mounted to one of the lowermost edges of the single prehung door assembly for elevating a bottom edge of the door slab above the ground; and
at least a first strap encircling the single prehung door assembly about at least one of the upper protective side caps or the lower protective side caps, wherein each of the upper and lower protective side caps includes a base panel, two side panels and an end panel together forming a U-shaped cavity closed at one end by the end panel, and wherein the right and left side jambs of the door frame are disposed in the U-shaped cavity between the two side panels of each of the upper and lower protective side caps, and
wherein each of the support spacers is disposed between the end panel of one of the pair of lower protective side caps and at least one of the side jambs of the door frame.

5. The single unit protective door package as defined in claim 4 , wherein each of the support spacers is a hexahedron disposed between the end panel of one the pair of lower protective side caps and one of the lowermost edges of the door frame.

6. The single unit protective door package as defined in claim 4 , wherein each of the lower protective side caps further includes an extension panel including a proximal extension section adjacent to the end panel, a distal extension section, and a middle extension section disposed between the proximal and distal extension sections, wherein the extension sections are connected to each other by folding lines, and wherein the extension sections of the extension panel are foldable relative to each other and the end panel so as to wrap over the spacer.

7. A unitized door packaging of a plurality of single unit protective door packages packaging a single prehung door assembly, the single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs, the unitized door packaging comprising:
the plurality of the single unit protective door packages stacked and aligned with each other, each of the single unit protective door packages comprising a single prehung door assembly including a pair of upper protective side caps each configured to be mounted to the single prehung door assembly at one of opposite upper corners of the door frame, a pair of lower protective side caps each configured to be mounted to the door assembly at one of lowermost edges of the door frame and a pair of support spacers each mounted to one of the lowermost edges of the door frame for elevating a bottom edge of the door slab above the ground; and
top and bottom tightening straps securing the plurality of stacked single unit protective door packages together by encircling the stacked single unit protective door packages over the upper and lower protective side caps, respectively, of the stacked single unit protective door packages;
the single unit protective door packages are aligned with each other so that bottom surfaces of the support spacers of the single unit protective door packages are aligned, wherein each of the support spacers includes a base member having a bottom surface adapted to engage a floor surface, and a top surface configured to engage one of the lowermost edges of the door frame of an associated single unit protective door package, and
wherein each of the support spacers further includes a connecting member and at least one support member extending outwardly from the top surface and wherein one of the right and left side jambs of each of the door frames is disposed between the least one support member and the connecting member of each of the support spacers.

8. The unitized door packaging as defined in claim 7 , wherein each of the support spacers has upper and lower parallel support surfaces.

9. A unitized door packaging of a plurality of single unit protective door packages, packaging a single prehung door assembly, the single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs, the unitized door packaging comprising:
the plurality of the single unit protective door packages stacked and aligned with each other, each of the single unit protective door packages comprising a single prehung door assembly including a pair of upper protective side caps each configured to be mounted to the single prehung door assembly at one of opposite upper corners of the door frame, a pair of lower protective side caps each configured to be mounted to the door assembly at one of lowermost edges of the door frame and a pair of support spacers each mounted to one of the lowermost edges of the door frame for elevating a bottom edge of the door slab above the ground; and
top and bottom tightening straps securing

Assignees

• Masonite Corp

Inventors

• Farish Steven
• Abbas Tom
• Burba Garrett
• Findley Randy
• Dusharm Keith
• Leo Rick

Classifications

• E06B7/28

  Other arrangements on doors or windows, e.g. door-plates, windows adapted to carry plants, hooks for window cleaners {(edge protecting devices for door leaves E06B3/88; special glazing; emergency glazing; double glazing E06B3/66)} · CPC title

• B65D85/64

  for bulky articles · CPC title

• B65B55/00

  Preserving, protecting or purifying packages or package contents in association with packaging (by packaging under special atmospheric or gaseous conditions B65B31/00; devices for placing protecting sheets, plugs, or wads over contents B65B61/22) · CPC title

• B65D63/00

  Flexible elongated elements, e.g. straps, for bundling or supporting articles {(attached to or integral with bags or sacks B65D33/165; for securing load B60P7/0823)} · CPC title

• B65D2585/649

  other bulky articles · CPC title