Patent Application
20160097233
The present invention relates to door frame members, in particular, garage door frames made from durable cellular polyvinyl chloride (PVC).
Traditional garage door frames are made from wood. The wood material has several disadvantages, including susceptibility to rotting, high upkeep, such as a requirement for regular re-painting, and difficulty in obtaining high quality lumber.
Garage door frames made from standard, or free foam, PVC materials are sometimes used in place of the traditional wooden garage door frames. However, free foam PVC frames are softer, damage easily, and expose air pockets when cut.
The present application relates to a door frame member for a garage door frame, made from a durable cellular PVC material, known as Celuka PVC, as described below.
According to one aspect of the present invention, a door frame member is provided made from a Celuka PVC material. The door frame member is comprised of a first structural element and a second decorative facing element. The first structural element is attached to the second decorative facing element by means of fusion welding.
In another embodiment of the door frame member according to the present invention, the second decorative facing element further has an attachment flange along the length thereof.
In another embodiment of the door frame member according to the present invention, the door frame member further comprises an intermediate spacing element. The first structural element is attached to one end of the spacing element and the second decorative facing element is attached to the opposing end of the spacing element.
In another embodiment of the door frame member according to the present invention, the door frame member is curved.
According to another aspect of the present invention, a door frame kit is provided, comprising three door frame members cut to specification for use as the jambs and upper transverse member of a door frame.
In order that the invention may be more clearly understood, preferred embodiments thereof will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
The term “Celuka PVC”, as used herein, refers to foamed polyvinyl chloride material with a hard outer surface made according to the Celuka extrusion process. The Celuka extrusion process for PVC involves extruding a PVC melt containing chemical blowing agents through a hollow die. As the extrudate exits the die, the outer surface of the extrudate is immediately cooled. This cooling suppresses cell formation at the surface of the extrudate, resulting in a hard, durable finish. The subsurface extrudate remains hot and expands inwardly to fill the profile shape of the die. The Celuka process results in a lightweight cellular PVC extrusion with a hard, durable outer shell.
A door frame member according to the present invention is proposed. The frame members 1 are preferably used as the jambs 2 and upper transverse member 3 of a garage door frame, as shown in
As shown in
The second decorative facing element 5 has a generally square-like or rectangular cross section and a length. The second decorative facing element 5 may have an attachment flange 7 extending from one end of its cross section and along the length thereof, which fits between the supporting structure of the garage door and the bricks of the building. The attachment flange 7 may be provided with apertures, for receiving fasteners to secure the frame member 1 to the supporting structure of the garage door. The decorative surface 8 of the second decorative facing element 5 may be shaped or otherwise ornamented to achieve the desired design aesthetic.
As shown in
As shown in
One end of each frame member 1 used as a jamb 2 is cut at an angle θ1. Both ends of each frame member 1 used as an upper transverse member 3 are cut at an angle θ2. Preferably, angle θ1 is complementary to angle θ2, so that when the cut ends of the frame members 1 are abutted, the upper transverse member 3 is disposed at a 90° angle to the jambs 2. Preferably, angle θ1 and angle θ2 are chosen so that the cut edges of each frame member 1 are the same length, for example, angle θ1 and angle θ2 may both be 45°. The relationship between angle θ1 and angle θ2 may also be expressed by the following equation:
θ1+θ2=90°
In another embodiment of the present invention, when one or more frame members 1 are curved, the angle θ1 is complementary to the angle θ2, so that when the cut ends of frame members 1 and one or more curved frame members 1a are abutted, the frame is complementary to the curved shape of the garage door. Preferably, where the garage door frame is arch shaped, the ends of the upper transverse member 3 are disposed along a line at a 90° angle to the jambs 2. In this embodiment, angle θ1 and angle θ2 depend on the distance between the jambs 2 and the radius of curvature of the curved frame member 1a used as the upper transverse member 3. Preferably, angle θ1 and angle θ2 are chosen so that the cut edges of each frame member 1 and curved frame member 1a are the same length. The relationship between angle θ1 and θ2 can also be expressed by the following equation:
θ1+θ2=180°−A°
where: A°=arccos(LHe/2 r);
According to another aspect of the present invention, a method is provided to manufacture a garage door frame. First, a plurality of first structural elements 4, made of a Celuka PVC material, are fusion welded to a plurality of second decorative facing elements 5, made of a Celuka PVC material, thereby creating a plurality of frame members 1. One end of two frame members 1 is cut at an angle θ1, as described above, for use as the jambs 2. Next, both ends of a frame member 1 are cut at an angle θ2, as described above, for use as an upper transverse member 3. Three frame members 1, two for use as jambs 2 and one for use as the upper transverse member 3, complete a garage door frame. The jambs 2 and upper transverse member 3 may then be installed within the support structure surrounding a garage. Preferably, fasteners are driven through apertures in the attachment flange 7 and into the support structure to secure the frame members 1 in place.
The jambs 2 and an upper transverse member 3 may also be made using frame members 1 that include an intermediate spacing element 6. In this embodiment, the frame members 1 are created by fusion welding a first structural element 4 to one end of a spacing element 6 and fusion welding a second decorative facing element 5 to the opposing end of the spacing element 6, as described above.
In order to create a curved frame member 1a, the method further comprises the steps of heating a frame member 1 to soften it, bending the frame member 1 into a curved shape, and cooling the frame member 1 to solidify it in its curved shape. Preferably, the frame member 1 is heated, in an oven, for 40-60 minutes, at a temperature of between 130° C. and 180° C. to soften it, so as to allow it to bend. The heated frame member 1 is then bent over a form of the desired shape and held in place while it cools to produce a curved frame member 1a. Preferably, the form has a constant arc with a radius of curvature of 144″, but other shapes and radii are possible. In this embodiment the angle θ1 and the angle θ2 are determined, as described for the corresponding embodiment of the frame member 1, above. The ends of the curved frame member 1a are then cut, for example, to create a curved upper transverse member 3 for an arch shaped garage door frame.
According to another aspect of the present invention, a door frame kit is provided with frame members made of Celuka PVC material. The kit has three frame members 1, two for use as the jambs 2 and one for use as the upper transverse member 3, as described above. The kit can then be assembled and installed in the garage door.
A number of embodiments of the present invention have been described. Nevertheless, the scope of the claims should not be limited by the preferred embodiments set out herein, but should be given the broadest interpretation consistent with the specification as a whole.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2887176 | Apr 2015 | CA | national |
| Number | Date | Country | |
|---|---|---|---|
| 62058182 | Oct 2014 | US |
