Patent Application
20240183215
The invention is directed to pocket doors used in residential and commercial properties and, in particular, to a pocket door frame assembly having a modular construction, allowing compact storage and shipping, and effortlessly assembly providing spacing advantages over conventional pock door frames.
A “pocket door” is commonly used in homes and offices to provide a unique space saving feature. Pocket doors can be hidden in a wall by use of a recessed compartment placed in a wall cavity. In modern home and building construction, partition walls are normally constructed from wood studwork covered with a wall skin, such as drywall, sheetrock, plasterboard or the like. The pocket door design requires a builder to leave space in the studwork for a doorway and also for an internal cavity into which a sliding door may be concealed. For this reason, typical pocket door frames include studwork for support of the wall skin. The door frame supports the outer skin of the wall providing wall strength, and providing a frame for the sliding door to travel within. The result is very good space saving characteristics and a contemporary design, as there is no encroachment of a conventional hinged door into the adjoining room. Modern designers realize this and, as a result, pocket doors have made a resurgence in recent years.
However, conventional pocket door frames are known to sag or outright fail over time due to inadequate construction design. The conventional frame relies upon a substandard support for the wall skin which will eventually allow warpage as the frame ages. The conventional frame employs a minimal amount of structural rigidity by relying upon adjacent wall panels for support. Further, conventional framing can be installed improperly, or damaged during installation, due to the required reliance on adjacent wall boards to provide reinforcement. Additionally, the framing can warp over time due to acclimation such as wood and wall board strength variation due to moisture affecting rigidity. Aluminum U-shaped channels were added in an attempt to correct the problem, but the channels can easily be damaged and relying upon adjacent wall boards for strength result in the same failures. Conventional pocket door frames use nails as fasteners which fail to permanently bond members together.
In light of the above, conventional pocket door frames eventually fail resulting in the pocket door rubbing on the frame and making it difficult to open or close. Once the framing for a pocket door fails the frame needs to be replaced, which is complicated task as part of the wall has to be opened. Due to the failure of conventional pocket door, the reputation of pocket doors has soured.
Conventional pocket door frames typically have oversized dimensions leading to a substantial rise in packaging and shipping costs. The excessively large pocket door frames pose logistical challenges as manufacturers are compelled to invest more resources in crafting packaging materials that can adequately accommodate these bulkier dimensions. Consequently, the increased size not only escalates the expenses associated with packaging materials but also necessitates larger shipping containers, resulting in elevated transportation costs. Addressing the challenge of oversized pocket door frames is pivotal for optimizing efficiency, cost-effectiveness, and sustainability within the industry.
To address the above mentioned shortcomings, Applicants co-pending patent application Ser. No. 18/470,056 provides an improved Pocket Door Frame Assembly, the contents of which is incorporated herein by reference. However, in instances where storage and shipping concerns require minimal space, there exists a need for a compact door frame assembly having a construction technique to address and eliminate pocket door frame warping frame while reducing the cost of materials and shipping.
Disclosed is a compact pocket door frame featuring a modular construction, allowing it to stored or shipped using compact packaging. The modular construction streamlines the packaging process and significantly reduces the overall dimensions of the shipped product. The user-friendly assembly enables a straightforward and efficient installation on-site, ensuring that the pocket door frame maintains structural integrity while minimizing packaging and shipping expenses. Such a solution not only addresses the logistical challenges faced by manufacturers but also enhances convenience for both distributors and end-users, ultimately fostering a more cost-effective and environmentally sustainable approach to pocket door frame transportation.
The pocket door frame includes a header support having a first end and a second end; first and second header spacers having a proximal end and a distal end, the header spacers secured to said header support and extending along the length of the header support; first and second header frame members secured to the first and second header spacers; a track fastened to a lower surface of the header support and nested between the first and second header spacers and the first and second header frame members, the track constructed and arranged to support a sliding door movable between a first and second end of said header support; a first vertical spreader spaced apart from a second vertical spreader by a first distance, each of the spreaders removably fastened, and extending from, the header support, and secured perpendicular to the proximal end of the header spacers; a base member having a having a front end and a back end forming a second length therebetween, the front end fastened to the first and second vertical spreader forming an opening sized to allow a sliding door to pass through the opening; a metal endplate attached to the second end of the header support, the metal endplate having a width measured between a first edge wall and a second edge wall; a first plywood panel positioned adjacent the first vertical spreader and extending from the base member to said header support and removably fastened to the header support; a first base block extending between the base member and the header support, the first base block secured to the first vertical spreader; a second plywood panel positioned adjacent the second vertical spreader and extending from the base member to the header support and removably fastened to the header support; a second base block extending between the base member and the header support, the second base block secured to the second vertical spreader; wherein the header support is removably fastened to the vertical spreaders for shipping and storage whereby said header support is secured to the vertical spreaders forming a T-shape structure for wall mounting to support a sliding door.
An objective of the invention is to provide an improved compact pocket door frame assembly that allows a header support shaped and sized to the width of vertical spreaders to fit together as one compact unit in order for the frame assembly to be packaged neatly in a vertical container.
Another objective of the invention is to provide an improved compact pocket door frame assembly using primed finger joint pine and plywood leading to long term dimensional stability.
Still another objective of the invention is to employ a header that is easily disassembled in order to reduce the size of packaging to lower shipping costs.
Yet still another objective of the invention is to provide a header with T-nuts, allowing ease of track installation and replacement.
Another objective of the invention is to use a proximal end of a header spacer attached to the header support as a proper fitting guide during installation, ensuring no side to side movement of the track.
Still another objective of the invention is to eliminate the need for a metal typically used for stability in a conventional frame.
Other objectives and advantages of this invention will from the following description become apparent taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.
A detailed embodiment of the instant invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the invention. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Referring now to the figures, illustrated is a compact pocket door frame 10 for a sliding door hung from a header support 12 having a length (L1) and a width (W1). The header support 12 spans from a first end 24 to a second end 26. A track 14 is attached to the header support 12 by use of a plurality of T-bolts 15 wherein a reciprocal fastener is removably attached to each T-bolt 15, allowing ease of track 14 maintenance or replacement.
A first header spacer 16 is positioned perpendicular to a lower surface of the header support 12 and extends outwardly from the pocket recess. A first header frame member 18 is positioned perpendicular to the first header spacer 16 and extends outwardly from the pocket recess. The first header spacer 16 is stapled and glued to the header support 12. The first header frame member 18 is stapled and glued to the first header spacer 16. A second header spacer 20 is positioned perpendicular to a lower surface of the header support 12 and extends outwardly from the pocket recess. A second header frame member 22 is positioned perpendicular to the second header spacer 20 and extends outwardly from the pocket recess. The second header spacer 20 is stapled and glued to the header support 12. The second header frame member 22 is stapled and glued to the second header spacer 20.
The track 14 is nested between the first and second header spacers 16, 20 and the first and second header frame members 18, 22. This region is referred to as the “pocket recess”. In a preferred embodiment, the pocket recess has a width of at least 4⅝ inches.
The first header spacer 16 and the first header frame member 18 attached thereto extend from a proximal end 28 to a distal end 30. In a preferred embodiment, the proximal end 28 is located close to the middle point of the header support 12, but the distance between the distal end 30 and the proximal end 28 may span any distance shorter than the distance between the first end 24 and the second end 26. During installation of the compact pocket door frame assembly 10, the proximal end 28 is used as a stopper to ensure no side to side movement of the track.
A first vertical spreader 32 and a second vertical spreader 34 extend from a base member 35 to the header support 12 in a spaced apart position. The first vertical spreader 32 is spaced apart from the second vertical spreader 34 by a first distance and each spreader 32, 34 is removably fastened and extending from the header support 12 and secured perpendicular to the proximal end 28 of said header spacers 16, 20. In a preferred embodiment, the base member 35 is made of ⅛ inch Polyethylene for reduced friction, damage prevention, corrosion resistance, low cost, and ease of installation. In this embodiment, the base member 35 has a thickness of ⅛ inch and a length of 14¾ inch.
Each vertical spreader 32, 34 is made from laminated 3% inch primed finger joint pine and is stapled and glued to the header support 12 forming a spaced apart opening of about 2¼ inches (W1). The first vertical spreader 32 forms an “L” shape by use of a laminated base block 36 forming a width (W2) of about 1½ inches with the base block 36 glued and stapled to the vertical spreader 32. Similarly, the second vertical spreader 34 forms an “L” shape by use of a laminated second base block 38 forming a width (W3) of about 1½ inches with the second base block 38 glued and stapled to the second vertical spreader 34.
The first and second vertical spreaders 32, 34 form a pocket recess entryway, or opening, constructed and arranged to receive a sliding door 40, shown in
A metal endplate 48 is attached to the second end 26 of the header support 12 having a width measured between a first edge wall and a second edge wall. This width is defined by the region where the compact pocket door frame assembly 10 is installed between two drywall panels. The purpose of the metal endplate 48 is to provide structural support and stability to the compact pocket door frame assembly 10, in particular, with sagging and flexing of the frame assembly 10. A detailed view of the metal endplate 48 is shown in
Along the first side of the compact pocket door frame assembly 10 is placed a first plywood panel 54 positioned adjacent to the first vertical spreader 32 and extending from the base member 35 to the header support 12, the plywood being ⅛ inch thick and about 14 inches wide, and being attachable to the header support 12 by securing screws or T-bolts through the top of the first plywood panel 54. The second side has a second plywood panel 56 positioned adjacent to the second vertical spreader 34 and extending from the base member 35 to the header support 12, the plywood being ⅛ inch thick and about 14 inches wide and fastened to each of the horizontal slats 34 positioned on the second side, and being attachable to the header support 12 by securing screws or T-bolts through the top of the second plywood panel 56.
The combination of the vertical spreaders 32, 34 and the plywood panels 54, 56 are positioned about halfway along the length of the header support 12. The header support 12 is removably fastened to the vertical spreaders 32, 34 for shipping and storage whereby the header support 12 is secured to the vertical spreaders 32, 34 forming a T-shape structure for wall mounting to support a sliding door 40.
As shown in
The term “about” means, in general, the stated value plus or minus 5%. The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more” or “at least one.” The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a method or device that “comprises,” “has,” “includes” or “contains” one or more steps or elements, possesses those one or more steps or elements, but is not limited to possessing only those one or more elements.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims.
In accordance with 37 C.F.R. 1.76, a claim of priority is included in an Application Data filed concurrently herewith. Accordingly, the present invention claims priority as a continuation-in-part of U.S. patent application Ser. No. 18/470,056, entitled “POCKET DOOR FRAME ASSEMBLY”, filed Sep. 19, 2023, which claims priority to U.S. Provisional Patent Application No. 63/382,911, entitled “POCKET DOOR FRAME ASSEMBLY”, filed Nov. 9, 2022. The contents of the above referenced applications are incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63382911 | Nov 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18470056 | Sep 2023 | US |
| Child | 18437774 | US |
