Patent Application
20200308899
The present invention relates generally to a corner support assembly for metal framed doors. More so, the present invention relates to a corner support assembly that provides a dimensionally stable reinforcement for fastening a metal door with molding, so that the door molding easily attaches to extruded vertical and horizontal frame members of the corner support assembly in a snap-fit relationship without the need for notching; whereby the frame members are secured into place with screws, welds, and threaded bolts; whereby shear blocks slide into mold installation grooves in the vertical frame member with screws at each corner; whereby the shear block has multiple holes that allow solder to be poured into the dedicated holes for a plug weld to fasten the shear blocks to the horizontal frame members; whereby the shear blocks help prevent shearing and increases structural integrity of the corner support assembly; whereby an elongated threaded bolt reinforces the connection between the horizontal and vertical frame members; and whereby a rubber glass setting block rests on the frame members to securely receive a glass pane.
The following background information may present examples of specific aspects of the prior art (e.g., without limitation, approaches, facts, or common wisdom) that, while expected to be helpful to further educate the reader as to additional aspects of the prior art, is not to be construed as limiting the present invention, or any embodiments thereof, to anything stated or implied therein or inferred thereupon.
Typically, commercial metal framed doors are supported within a metal framework. Often the metal frame is made of aluminum extrusions. The metal framework is configured to form corner joints between the horizontal and vertical frames. Often, these commercial metal framed doors undergo heavy use which can torque the metal configuration. This shearing force creates a great amount of stress at the door corner joints. In many instances, commercial doors utilize corner joints that can withstand such forces. However, the corner joint can be bulky and cumbersome, and subject to failure from the shearing and torqueing forces which result from heavy duty use of the commercial metal door.
Other proposals have involved metal commercial door support frameworks. The problem with these door support frameworks is that they do not have multiple fastening means. Also, they require the door molding to be notched to mount the support structure. Even though the above cited door support frameworks meet some of the needs of the market, a corner support assembly for metal framed doors provides a dimensionally stable reinforcement for fastening a metal door with molding, so that the door molding easily attaches to extruded vertical and horizontal frame members of the corner support assembly in a snap-fit relationship without the need for notching; whereby the frame members are secured into place with screws, welds, and threaded bolts, is still desired.
Illustrative embodiments of the disclosure are generally directed to a corner support assembly for metal framed doors. The corner support assembly provides a dimensionally stable reinforcement for fastening a metal door with a door molding, so that the door molding easily attaches to extruded vertical and horizontal frame members of the corner support assembly in a snap-fit relationship without the need for notching. The horizontal and vertical frame members are secured into place with both screws and welds.
Shear blocks are used at the intersection of the vertical and horizontal frame members to help prevent shearing and increase structural integrity of the corner support assembly. The shear blocks are configured to slide into grooves in the vertical frame member and remain fastened in place. At least one shear screw, a fillet weld and a shear block at each corner help secure the frame members.
The shear block has multiple holes that allow solder to be poured into the dedicated holes for a plug weld to fasten the shear blocks to horizontal frame members. An elongated ⅜″ threaded bolt reinforces the connection between the horizontal and vertical frame members. A rubber glass setting block is applied on the inside of frame members for full glass edge protection.
In one aspect, a corner support assembly for metal framed doors, comprises:
In another aspect, the frame members are extruded.
In another aspect, the vertical frame members include at least one of the following dimensions: 2″×1¾″×⅛″; and 3½″×1¾″×⅛″; and 5″×1¾″×⅛.
In another aspect, the horizontal frame member includes at least one of the following dimensions: 2″×1 11/16″×⅛″, 3½″×1 11/16″×⅛″, 5″×1 11/16″×⅛″, 7½″×1 11/16″×⅛″, and 10″×1 11/16″×⅛″.
In another aspect, the vertical and horizontal molding installation grooves mate with the door frame.
In another aspect, the threaded bolt comprises a ⅜″ zinc plated steel threaded rod.
In another aspect, the bolt nut comprises a ⅜ inch-16 zinc plated nut.
In another aspect, the shear screw comprises a ¼ inch-20×1 inch zinc plated stainless steel socket cap head screw.
In another aspect, the plate comprises a zinc plated steel mounting plate.
In another aspect, the plug weld comprises a 7/32″ plug weld.
In another aspect, the fillet weld has a length up to 1⅛ inches.
In another aspect, the door frame supports a metal door.
In another aspect, the metal door comprises a ¼ inch or a 1 inch insulated pane of glass.
In another aspect, the assembly further comprises a glass setting block operable to receive the pane of glass, the glass setting block resting on the top wall of the horizontal frame members.
In another aspect, the glass setting block is fabricated from rubber.
In another aspect, the dimension of the glass setting block comprise ¾ inch×1 inch×¼ inch.
In another aspect, the assembly comprises an adhesive applied on the self-tapping screw.
In another aspect, the self-tapping screw comprises a #10—16×¾ inch self-tapping hex washer head zinc plated steel screw.
One objective of the present invention is to support a metal framed door in a corner of a structure.
Another objective is to provide the strongest fastening and welding in regard to the assembly of aluminum commercial doors.
Yet another objective is to allows for a long fillet weld at all connection corners up to 1⅛″ in length of continuous fillet weld without any notching or modification to the door vertical rails, top rails, bottom rails, mid rails, and the door moldings.
Another exemplary objective is to allow for compressing, connecting, and fastening all vertical rails and all top & bottom rails together with a ⅜″-16 zinc plated steel threaded rod, so as to insure enhanced fastening strength and back up fastening.
Additional objectives are to slide the shear block into the door vertical rails, insuring a stronger connection between the heavy shear blocks to the door vertical rails.
Another exemplary objective is to provide an inexpensive to manufacture corner door assembly.
Other systems, devices, methods, features, and advantages will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims and drawings.
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Like reference numerals refer to like parts throughout the various views of the drawings.
The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure, which is defined by the claims. For purposes of description herein, the terms “upper,” “lower,” “left,” “rear,” “right,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in
A pair of horizontal and vertical frame members 102a-b, 118a-b are arranged to join at their ends 116a-b, 130a-b to form a rectangular shape, which is sized and dimensioned to supportively receive a door frame of the metal door. Horizontal and vertical frame members 118a-b, 102a-b are defined by multiple guide lines 170a-b, 106a-b that help with manual fabrication of the metal door.
Additionally, a heavy shear block 136a-d provides structural integrity to the assembly 100. Shear block 136a-d abuts the intersection of horizontal and vertical frame members 118a-b, 102a-b, sliding between molding installation grooves 168a-b that form in the vertical frame member 102a-b. Shear block 136a-d and horizontal and vertical frame members 118a-b, 102a-b are secured into place with multiple fastening means, including at least one of: a shear screw 156a-f, a fillet weld 200a-b, and a plug weld hole 158. Further, at least one elongated threaded bolt 160a, 160b passes between the vertical and horizontal frame members 118a-b to reinforce the connection therebetween. At least one rubber glass setting block 800a-1 rests in the frame members to receive a pane of glass 802 in a secure manner. The metal door may include a commercial aluminum door, with or without a glass pane. Though in other embodiments, any door or gate, metallic or non-metallic, which requires rigid structural support for operation, may also be mated to assembly 100.
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In some embodiments, vertical frame members 102a-b comprise extruded aluminum alloy series 6063-T6 temper. Vertical frame members 102a-b may also be anodized (AAMA 611—Class 1) to formulate specific colors. The dimensions of vertical frame members 102a-b may include, without limitation, 2″×1¾″×⅛″; and 3½″×1¾″×⅛″; and 5″×1¾″×⅛. However in other embodiments, different materials and dimensions may also be used, as assembly 100 is scalable to accommodate variously sized metal doors.
Top wall 104a-b of vertical frame members 102a-b is defined by multiple vertical molding installation grooves 168a, 168b. Vertical molding installation grooves 168a-b are sized and dimensioned to receive the door molding in a snap-fit mating relationship; thereby negating the need to notch the vertical frame members 102a-b or the door molding to create the connection. The top wall 104a-b is further defined by a vertical frame bolt hole 108 and a vertical frame fastener hole 110, which are both used to enable passage of various fasteners there through (
As
Continuing with
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In some embodiments, multiple horizontal guide lines 170a, 170b are disposed longitudinally along the top wall of horizontal frame members 118a-b. In one non-limiting embodiment, three horizontal guidelines pass in a parallel relationship across the top wall 120a-b.
As
Looking again at
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As discussed above, the assembly 100 is configured to securely retain a metal door within the horizontal and vertical frame members 118a-b, 102a-b. Thus, in one possible embodiment, at least one fillet weld 200a, 200b is applied at the intersection of the shear block 136a-d, the vertical frame member 102a-b, and the horizontal frame member 118a-b. Fillet weld 200a-b holds frame members 102a-b, 118a-b at a perpendicular to each other. Fillet weld 200a-b may have a length up to 1⅛″. Though in other embodiments, other weld lengths are possible.
As illustrated back in
The difference in plate lengths is engineered per the horizontal members top wall and bottom wall to provide a more stern compression of the horizontal members between the vertical members. The plate threaded fastener holes 1002, 1008 protrude ⅛″ at the rear of the plate beyond the plate's ⅛″ thickness to ensure further fastening strength between the plate and the shear screw. The plate bolt hole also protrudes ⅛″ at the rear to provide proper mechanical operation for the tightening of the nut and also strengthens the integrity of the plates 1000a, 1000b.
In some embodiments, at least one shear screw 156a-f passes through shear fastener hole 144 and the plate fastener hole 152. In one embodiment, two shear screws 156a, 156b, 156c, 156d, 156e, 156f pass through each side of shear blocks 136a, 136b, 136c, 136d. Shear screw 156a-f helps fasten shear block 136a-d to vertical frame member 102a-b and/or horizontal frame member 118a, 118b. In one non-limiting embodiment, shear screw 156a-f comprises a ¼″-20×1″ zinc plated stainless steel socket cap head screw. Though in other embodiments, different dimensions are possible. And other screw/bolt/washer/nut fastening mechanisms may also be used.
In addition to shear screw 156a-f, another fastening means for securing shear block 136a-d is at least one plug weld hole 158 (
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In one embodiment the metal door can fasten to the frame members 102a-b, 118a-b through shear block 136a-d and threaded bolt 160a-b. In another embodiment, metal door can fasten to frame members 102a-b, 118a-b through shear block 136a-d and self-tapping screws 134a-d. In yet another embodiment, metal door can fasten to frame members 102a-b, 118a-b through shear block 136a-d, fillet weld 200a-b, and plug weld hole 158. Thus metal door may be fastened by only one, two, or all three fastening means.
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After the vertical frame members are spaced apart to the desired width, the method 1200 further includes a Step 1204 of aligning a pair of horizontal frame members in a horizontal orientation, the horizontal frame members comprising a top wall defined by multiple horizontal molding installation grooves, a bottom wall, sidewalls, and ends. At this point, the horizontal and vertical frame members form a generally rectangular shape that is sized and dimensioned to receive a metal door. A Step 1206 includes joining the horizontal and vertical frame members at the ends to form a rectangular shape. This is not a permanent fastening, but a temporary one until the appropriate screws, bolts, and welds are applied.
In some embodiments, a Step 1208 comprises sliding at least one shear block into the ends of each vertical frame members by sliding the shear block rails into the vertical frame members multiple molding installation grooves. The shear blocks slide in, at the ends of each vertical frame members by sliding the shear block rails into the vertical frame members multiple molding installation grooves. With the at least one shear block abutting the top wall of all the vertical frame members at all ends, the shear block aligns with #1 or #2 fastener holes and the shear block bolt hole. The shear block also aligns with the vertical frame members #1 or #2 fastener holes and the vertical frame members bolt hole. At this point all four of the shear blocks are secured in place.
Now to achieve a more precise fastening the vertical and horizontal frame members, a Step 1210 includes aligning the shear block fastener holes and the shear block bolt hole, with the vertical frame members fastener holes and the vertical frame members bolt hole. Then, in some embodiments, a Step 1212 may include sliding a mounting plate into a vertical frame member open space until the mounting plate aligns with the threaded fastener holes and a mounting plate bolt hole, and further aligns with the shear block and a vertical frame member fastener hole and multiple shear block and vertical frame members bolt holes. The mounting plate may include a flat, rigid Zinc plated metal mountain plate. Though in other embodiments different kinds of metals and plates can be.
In beginning to fasten the components, a Step 1214 comprises passing at least one shear screw through the shear block fastener holes and the vertical frame member fastener holes, whereby the shear screw fastens the mounting plate through the threaded fastener holes. The method 1200 may further comprise a Step 1216 of passing the hex head self-tap screw through the horizontal frame member in the at least one fastener hole, on the horizontal frame member top wall and bottom wall, whereby the hex head self-tap screw fastens into the shear block at a shear block fastener pilot hole. The hex head self-tap screw is the type of screw that does not need a nut or a washer. Thus, this is effective for passing through the horizontal frame member fastener holes.
Continuing with the assemblage, a Step 1218 includes welding at least one fillet weld at the intersection of the vertical frame members and the horizontal frame members, between the fastened vertical frame members top walls and the fastened horizontal frame members top walls and bottom walls. The fillet weld provides a very secure fastening mechanism between the horizontal and vertical frame members, creating both lateral and axial stability. The 1⅛″ fillet weld welding all fastened vertical frame members to all fastened horizontal frame members. A Step 1220 includes passing at least one shear screw through the shear fastener hole to help fasten the shear block to the vertical frame member. This process is now done for all shear blocks, fastening each shear block to the vertical frame member top wall on each end of both vertical frame members. This creates the attachment of the shear block to the vertical frame member.
The method 1200 may further comprise a Step 1222 of driving at least one elongated threaded bolt between the top wall of the vertical frame members, the threaded bolt passing through open space in the horizontal frame members. The threaded bolt is elongated, and sufficiently rigid to create a solid lateral fastening mechanism for the corner door assembly 100. The threaded bolt may include a ⅜″ zinc plated steel threaded rod.
The threaded bolt passes through one of the shear block bolt hole, and then through the vertical frame member bolt hole. The threaded bolt also passes through the zinc plated steel mounting plate bolt hole, extending one end of the ⅜″ zinc plated threaded rod into the vertical frame member open space, approximately 1″ beyond the vertical frame member top wall. A bolt nut is then attached to one end of the vertical frame members open space, at the same end of the vertical frame member with the ⅜″ zinc plated steel threaded rod. The bolt nut mates with the ⅜″ zinc plated steel threaded rod.
The assemblage requires taking the opposite end of the same ⅜″ zinc plated steel threaded rod, and placing the other end of the same ⅜″ zinc plated steel threaded rod through. The threaded rod is to pass through one end of the horizontal frame member open space, and out the other end of the horizontal frame member open space. At this point one end of the same horizontal frame member is placed on the vertical frame member top wall, by passing the already fastened shear block thru the horizontal frame member open space, and butting the one end of the same horizontal frame member with the top wall of the vertical frame member. The fastened shear block fastener pilot holes are aligned with the horizontal frame member fastener holes. This process is repeated at the opposite end of the same vertical frame member.
The same vertical frame member fastens to both horizontal frame members at the aligned ends, with at least one hex head self-tap screw. The at least one hex head self-tap screw goes through the horizontal frame member at the at least one fastener hole, on the horizontal frame member top wall and bottom wall. The hex head self-tap screw also fastens into the shear block at the shear block fastener pilot hole. The hex head self-tap screw fastens the horizontal frame members with the fastened shear blocks at the aligned ends.
Next, the opposite end of the ⅜″ zinc plated steel threaded rods are positioned between the shear walls of the already fastened shear block on the other vertical frame member. Upon resting both the ⅜″ zinc plated steel threaded rods other ends in between the shear blocks shear walls, the shear blocks are guided on the other vertical frame member, into both horizontal frame members open space, on each other ends of both horizontal frame members. They are guided in a way that disposes the shear blocks half way into the horizontal frame members open space.
Then, one of the other ends of one of the ⅜″ zinc plated threaded rods is guided through the fastened shear block bolt hole. The ⅜″ zinc plated threaded rod then passes through the other vertical frame members bolt hole, and lastly through the zinc plated steel mounting plate bolt hole and into the other vertical frame members open space, extending one of the ⅜″ zinc plated steel threaded rods other end, approximately 1″ beyond the top wall of the other vertical frame member.
In doing so the other ends of one of the horizontal frame member are aligned with the top wall of the vertical frame member, aligning the at least one fastener hole, on the other end of the horizontal frame member, with the at least one shear block fastener pilot hole of the fastened shear block. In doing so the other end of the horizontal frame member butts with the top wall of the other vertical frame member, at the corner where the other end of one of the ⅜″ zinc plated steel threaded rods is in the other vertical frame members open space. A bolt nut is then placed in the other vertical frame members open space, mating the bolt nut with the ⅜″ zinc plated steel threaded rod, at the corner where the other end of the one of the ⅜″ zinc plated steel threaded rods in the other vertical frame member's open space. Here, the bolt nut is tightened lightly.
The same process is repeated on the other end of the same other vertical frame member. Then all bolt nuts are tightened in all the vertical frame member's open space, fastening all vertical frame members to all horizontal frame members. The hex head self-tap screw then passed through the fastener hole, on the top wall and bottom wall of the other ends of both horizontal frame members. The hex head self-tap screw fastens into the already fastened shear blocks, shear block fastener pilot holes on the other vertical frame member, fastening both horizontal frame members other ends to the already fastened shear blocks.
In some embodiments, a Step 1224 includes drilling a 5/32×⅛″ deep shear plug weld hole in all the fastened shear blocks, at the shear blocks abutment wall ends on the fastened horizontal frame members top walls and bottom walls. A Step 1226 comprises pouring solder through the plug weld hole to the top wall or the bottom wall of the horizontal frame member. This process is now done at all of at least one 7/32″ plug weld holes on all fastened horizontal frame members top walls and bottom walls, welding all fastened horizontal frame members with all the fastened shear blocks.
A Step 1228 includes applying a glass setting block with existing adhesive over the hex head self-tap screws, the glass setting blocks comprising screw head punch outs. Upon applying all glass setting blocks with existing adhesive over all hex head self-tap screw heads, on all the fastened horizontal frame members top walls and bottom walls and all the fastened vertical frame members top walls. The glass setting block with existing adhesive is applied on all the fastened vertical frame members top walls, measuring up about 1″ from all fastened horizontal frame member's top walls with the measuring ending at the beginning edge of the glass setting block with existing adhesive. At this point, all the glass setting blocks are applied to all the fastened horizontal frame members bottom walls. And all the glass setting blocks are applied to the fastened horizontal frame members top walls, and all the fastened vertical frame members top walls.
In some embodiments, a Step 1230 may include mating a door molding on an interior side of a metal framed door, and with the multiple molding installation grooves, whereby the door molding snapping into the molding installation grooves. The horizontal door moldings are installed on the interior side of the metal framed door into the multiple molding installation grooves first. Then the vertical door moldings are installed on the interior side of the metal framed door into the multiple molding installation grooves, upon installing all the door moldings on the interior side of the metal framed door. A Step 1232 may include placing an insulated pane of glass into an open space of the metal framed door, whereby the pane of glass rests on the installed door moldings on the interior side of the metal framed door, and on top of the glass setting blocks.
A final Step 1234 comprises installing the horizontal door moldings on the exterior side of the metal framed door, and into the molding installation grooves on the exterior side of the metal framed door, whereby the door moldings help secure the glass pane in place. Then the vertical door moldings are installed, on the exterior side of the metal framed door, into the multiple molding installation grooves on the exterior side of the metal framed door. At least one glass setting block 800i, 800j rests on the exterior side of the door. At this point in the assemblage, all the installed door moldings are fully securing the glass pane within the metal framed door open space.
Although the process-flow diagrams show a specific order of executing the process steps, the order of executing the steps may be changed relative to the order shown in certain embodiments. Also, two or more blocks shown in succession may be executed concurrently or with partial concurrence in some embodiments. Certain steps may also be omitted from the process-flow diagrams for the sake of brevity. In some embodiments, some or all the process steps shown in the process-flow diagrams can be combined into a single process.
These and other advantages of the invention will be further understood and appreciated by those skilled in the art by reference to the following written specification, claims and appended drawings.
Because many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.
