Patent Grant
7204059
The present invention relates generally to devices which are designed to protect door jamb assemblies, and objects being moved through openings in which such door jamb assemblies are installed. The invention relates particularly to devices which are temporarily and removably mounted to doorjamb assemblies during periods when the door jamb assemblies are susceptible to elevated risk of damage.
Door jamb assemblies are assembled at manufacturing locations. Such door jamb assemblies require protection during shipping in the ordinary stream of commerce.
Individuals, families, and businesses commonly move from one location to another. Typically, a wide variety of belongings are moved with them. In addition, individuals, families, and businesses purchase items which, at times, can be large and bulky. These items, such as appliances, furniture, office equipment, and the like, are used to aid and assist the purchaser as well as provide for a comfortable and workable environment.
Moving such bulky and/or massive items can be a challenge. Due to the great weight of many such items, in combination with their sometimes awkward size, moving such items through a doorway can entail significant risk that the item being moved through the doorway will impact upon the door jamb assembly. This contact and engagement can cause damage not only to the door jamb assembly, but also to the item being moved through the doorway.
Similarly, during construction of new buildings, or renovation of buildings, exterior door jambs and door trim, namely door jamb assemblies, are typically installed about the door openings early in the construction process, and well before the remainder of the construction process is completed. Further, it is common to install a temporary door slab during the construction process, so the door can be closed and locked to exclude unauthorized entry to the building during the construction period.
In addition to security considerations, such early installation of a door jamb assembly facilitates installation of building materials which interface with, or otherwise cooperate with, the door jamb assembly. Also typically, once the door jamb assembly is installed, other building components are assembled to the building in cooperation with the jamb assembly such that subsequent removal of the jamb assembly for repair or replacement is an especially costly, and therefore undesirable, undertaking.
Where a door slab is installed, and is used during the construction project, it is common to install a temporary door slab of low aesthetic quality, whereby any damage done to the door slab is generally inconsequential. A permanent door slab is then installed in place of the temporary door slab as one of the last items in the construction project. By so withholding installation of the permanent door slab until very close to the end of the construction project, the chances for damaging the permanent door slab, as part of the construction project, are greatly reduced.
Indeed, during the ongoing phase of the construction project, a wide variety of workers, inspectors, owners, and other affected parties enter and leave the premises. During such ingress and egress, such persons move a wide variety of construction materials and equipment, such as table saws, tool boxes, air compressors, air hoses, extension cords, lights, ladders, dry wall, molding, appliances, cabinets, flooring, and the like, through the limited cross-section opening at the doorway. Inevitably, the door jamb elements and/or door trim elements of the finished door jamb assembly are struck, rubbed, abraded, or the like, and thus damaged by the materials and equipment passing through the door opening. In addition to the damage caused to the door jamb assembly, such contact can also cause damage to the items being moved through the doorway.
All the above disturbances to both the door frame, and materials and products potentially damaged by impact with the door frame, typically applies to all the door frames at all the respective doors in the building. Consequently, as the completion of e.g. the construction project, or the moving project, or the bringing in of newly-acquired items, approaches, the damaged door jambs and/or door trim must typically be repaired. In some cases, the repair can be done on site, while the respective jamb assembly remains assembled to the building.
Normally, however, such repair entails removing the damaged door jambs and trim from the rough opening and replacing them with new door jambs and trim. Such repair or replacement, whether on site or off site, must be done by skilled craftsmen. As suggested above, where an exterior doorway is to be repaired, removal of the door jamb assembly can involve removal of selected portions of siding and sheathing around the door opening, which seriously disrupts the smooth flow of completion of the construction project. In addition, even temporarily removing the jamb assembly significantly increases the cost of securing the building against unauthorized entry while the door jamb assembly is removed from the door opening.
In addition to the above, the damage may or may not be susceptible to repair, whereby the damaged door jamb assembly may have to be replaced by a new door jamb assembly.
Even if the jamb assembly can be repaired, such repair entails considerable time and expense, not to mention inconvenience to both the building occupant and the contractor responsible for the construction project. Further, the quality of the repair is commonly less than the quality of the original factory manufactured product.
The longitudinal edges of the door jamb assemblies, including door trim, are thus particularly vulnerable to damage when contacted by materials or equipment. In order to protect such edges, a guard may be placed over the finished door jamb assembly until the construction project, or moving project, or other project which elevates the risk of damage to the door jamb assembly, has been completed.
A substantial variety of guard structures are known for protecting door jamb assemblies. While certain known temporary guard structures have certain beneficial features, certain such structures do not accommodate closure of the door slab while the protective guard structure is installed on the door jamb assembly, thus failing to prevent unauthorized entry.
Other known structures accommodate closure of the door slab while temporarily reducing clearance between the door slab and the guard on the jamb assembly, by imposition of the guard structure into the clearance space normally available to accommodate modest mounting tolerances normally in effect for mounting the door slab in the jamb assembly. Thus, such other structures require the door slab to share the normal clearance space, between the door slab and the jamb assembly, with the thickness of the guard. In such instance, any variation from target clearances about the opening, with respect to the door slab to be installed therein, when the jamb assembly is fabricated, or any tolerance-type variation in the door slab or the jamb assembly, are exaggerated by the reduced magnitude of the nominal clearance between the door slab and the jamb assembly, which increases the potential for difficulty in actually getting the door slab to close on the opening.
One can, of course, specify/design an increase in the clearance between the door slab and the jamb assembly in order to allow for the thickness of the guard structure. However, such increased clearance between the door slab and the jamb assembly remains, as an excessive clearance, when the temporary guard is removed, whereby the user of the building can perceive the door slab as being too loose, not properly fitted to the jamb assembly. Thus, in conventional technology, the promise of a temporary guard wherein the door slab can be closed on the opening with the guard installed, is accompanied by excessively close clearances with the temporary guard installed and/or excessively wide clearances when the temporary guard is removed.
Accordingly, it is an object of the invention to provide a temporary door jamb assembly guard, and a door jamb assembly so guarded, wherein a door-side leg section of the guard extends along the door arresting surface of the jamb assembly.
It is another object of the invention to provide a temporary door jamb assembly guard wherein an outer leg section of the guard, extending from a central section of the guard, has a substantially greater length than a door leg section of the guard.
Yet another object of the invention is to provide a temporary door jamb assembly wherein the outer leg section comprises a resiliently cushioning nose member extending, along an arcuate path, outwardly from an underlying trim element at the outer surface of the door jamb assembly.
A further object is to provide a temporary door jamb assembly guard having a transition section between the central section and the outer section, wherein the transition section preferentially transfers forces exerted thereagainst, e.g. by impact with articles moving through the doorway, away from the door opening and toward the door jamb and/or the brick mold, or equivalent.
A more specific object is to provide such temporary door jamb assembly guard, having transfer webs, or other support structure, receiving such forces from the transfer section and transferring such forces to underlying elements of the door jamb and/or trim element at locations displaced from the transition section.
It is still another object of the invention to provide a method of temporarily protecting a door jamb assembly, including installing, on the jamb assembly, a guard having a door-side leg section which terminates in the vicinity of the door arresting surface of the jamb assembly, without interfering with typical clearance between the door slab and the jamb assembly when the door slab is closed on the doorway opening.
Still another object is to provide a jamb assembly guard, and method of use, the jamb assembly guard having a central section, an outer leg section, and a transition section between the outer leg section and the central section, and further optionally including support structure underlying the transition section, which support structure transfers forces, which are imposed on the transition section, to underlying surfaces of the jamb and/or a trim element.
In general, the invention comprehends removable door jamb assembly guards, guarded jamb assemblies, and methods of controlling a doorway opening e.g. in a building. The guard generally covers the full length of the jamb assembly, along the left side, right side, and preferably along the top, of the jamb assembly, and the full width of the jamb assembly between an outer trim element, such as a brick mold, and the door-arresting surface of the jamb. The guard has a central section, a door leg section, an outer leg section disposed outwardly of the central section, and optionally a transition section between the central section and the outer leg section. Preferred embodiments of the guard can be installed on a jamb assembly while a conventional door slab is mounted to the jamb assembly, and the door slab can be closed and opened without the guard interfering with such operation of the door. In the alternative, the guard can be installed on the jamb assembly as early as before the jamb assembly is mounted in the doorway of a building, and the door slab subsequently installed on the jamb assembly, either before or after the jamb assembly is mounted in the doorway of the building.
In a first family of embodiments, the invention comprehends a temporary door jamb assembly guard for installation over, and for temporarily protecting, a door jamb assembly, optionally while the door jamb assembly is attached to a wall which defines a door or doorway opening, during a period when such door jamb assembly is susceptible to an elevated level of risk of damage. The door jamb assembly has an inner-facing surface for facing into the door opening, a door-arresting surface, and an outer surface facing away from the door-arresting surface. The inner-facing surface extends from the door-arresting surface to the outer surface. The temporary door jamb assembly guard comprises a central section which overlies the inner-facing surface of the door jamb assembly, the central section having a first door side, and a second opposing side displaced from the door side; a door leg section, connected to the central section at the first door side; and an outer leg section, directly or indirectly connected to the central section at the second side facing away from the door. The door leg section has a first length between the first door side of the central section and an opposing distal edge of the door leg section, the outer leg section having a second length, substantially greater than the first length, between the second side of the central section and an opposing distal edge of the outer leg section.
In preferred embodiments, the guard can be installed on a doorjamb assembly, and a conventional door slab, mounted to the door jamb assembly, can be operated normally, namely closed and opened, with the guard so installed, without interfering with operation of the door slab.
Also in preferred embodiments, the guard is designed and configured to fit over, and protect, an outer trim element which is part of the door jamb assembly.
In some embodiments, the outer leg section comprises an interface member connected to the central section at the second side which faces away from the door. The interface member is sized and configured to extend at a transverse angle to the central section. The interface member is arranged and configured such that the interface member can extend over, and overlie, at least a portion of the outer surface of the door jamb assembly, the outer leg section further comprising a resiliently cushioning nose member extending outwardly in front of the interface member. A cavity is optionally defined between the interface member and the resiliently cushioning nose member.
In some embodiments, the door jamb assembly guard covers less than the entirety of a width of the inner-facing surface of the door jamb assembly for which the guard has been designed and configured.
In some embodiments, the guard further comprises a break-away cover tab, extending from a distal end of the outer leg section, and adapted to extend over an outer face of a trim element of the jamb assembly, with a line of weakness at the distal end of the outer leg section.
In other embodiments, the guard comprises a break-away cover tab, extending from a distal end of the outer leg section, and adapted to extend over an outer face of a trim element of the jamb assembly, with a line of weakness at a locus overlying an outer surface of the trim element adjacent, but displaced from, the distal end of the outer leg section.
In some embodiments, the outer leg section extends in an arcuate outer surface to an under-curled cushioning distal end.
In some embodiments, the outer leg section comprises a separate cover tab element adapted to cover an outer face of a trim element of the door jamb assembly.
In some embodiments, the guard comprises a first outer leg member, and a second outer leg member attached to the first outer leg member at a locus displaced from a distal edge of the first outer leg member.
In preferred embodiments, the door leg section is designed and configured to fit, on a correspondingly configured door jamb assembly, between the door-arresting surface and a weather strip element mounted proximate the door arresting surface.
In some embodiments, the central section comprises inner and outer section elements, for adjusting said jamb assembly guard according to thickness of a jamb assembly between the door-arresting surface and the outer surface. The inner and outer central section elements interlock with each other to establish an adjusted width of the central section corresponding to the thickness of the jamb assembly. The outer leg section is disposed relatively inwardly of the door opening and interfaces with the door-arresting surface. The inner and outer sections are slidingly engageable with each other to cause the inner and outer sections to grippingly engage the door-arresting surface and the outer surface of the jamb assembly, thus to custom adjust width of the central section of the guard to fit the thickness of the respective jamb assembly.
In the alternative, the central section can comprise a line of weakness extending along the length of the central section, wherein the line of weakness facilitates separating the guard into inner and outer sections, as by tearing or breaking at the line of weakness, overlapping the pieces with respect to each other to fit the thickness of the jamb assembly, then securing the inner and outer pieces of the central section to each other to maintain the fitted thickness.
In some embodiments, the guard comprises a transition section between the central section and the outer leg section.
In some embodiments, the central section comprises a release ridge, extending along a length thereof, which release ridge is displaced from an underlying jamb by a distance greater than a base distance by which a remainder of the central section is displaced from the jamb.
In a second family of embodiments, the invention comprehends the door leg section being connected to the central section at the first door side and being sized and configured to extend at a transverse angle to the central section along the door-arresting surface, and the outer leg section being sized and configured to extend at a transverse angle to the central section.
In a third family of embodiments, the guard comprises a transition section between the central section and the outer leg section. The transition section comprises an overlying contact structure directly interfacing with objects which impact on the transition element, and underlying support structure adapted and configured to interface with underlying surfaces of the jamb assembly. The transition section extends between an outer corner of the jamb and an outer corner of any trim element which is part of the jamb assembly, for example and without limitation, at an outer surface of the building at the doorway, and is effective to absorb and distribute forces imposed thereon so as to attenuate damage to the jamb assembly.
In some embodiments, the door leg section terminates at a distal edge thereof which comprises a distal edge of the guard, and which is consistent with termination of the guard in the vicinity of, and protecting, the door arresting surface.
In some embodiments, the guard further comprises a flex joint in the outer leg section, operative for rotating a distal edge of the outer leg section away from an underlying element door jamb assembly.
In some embodiments, the contact structure comprises a contact structure, such as a contact web, extending between first and second sides thereof at the outer leg section and the central section, the underlying support structure comprising at least one transfer web, extending from one of the first and second sides of the contact structure in a direction along at least one of (i) a surface of a trim element or (ii) an outer surface of the jamb.
In some embodiments, the contact structure comprises a contact web, and the underlying support structure comprises a transfer web extending from the contact web along an outer surface of the door jamb assembly to a locus proximate an intersection of the outer face of a trim element and an adjoining surface of the trim element.
In some embodiments, the support structure of the transition section is adapted and configured to reside in a cavity defined between the contact structure, an inner facing surface of the trim element, and an outer surface of the jamb, and to transfer forces from the contact structure to underlying surfaces of the trim element and the jamb at locations away from outer corners of the trim element and the jamb.
In some embodiments the underlying support structure comprises transfer webs connected to the contact structure and to each other to define a cavity between the transfer webs and the contact structure, and further comprising support webs extending between the contact structure and at least one of the transfer webs.
In a fourth family of embodiments, the invention comprehends a temporary door jamb assembly guard for installation over, and for temporarily protecting, a door jamb assembly, optionally while the door jamb assembly is attached to a wall and which defines a door or doorway opening, during a period when the door jamb assembly is susceptible to an elevated level of risk of damage. The door jamb assembly has an inner-facing surface for facing into the door opening, a door-arresting surface, and an outer surface facing away from the door-arresting surface. The inner-facing surface extends from the door-arresting surface to the outer surface. The temporary door jamb assembly guard comprises a central section which overlies the inner-facing surface of the door jamb assembly, the central section having a first door side, and a second opposing side facing away from the door side; a door leg section, connected to the central section at the first door side and sized and configured to extend at a transverse angle to the central section along the door-arresting surface of the door jamb assembly; and an outer leg section directly or indirectly connected to the central section at the second side facing away from the door, the outer leg section comprising an interface member sized and configured to extend at a transverse angle to the central section, the interface member being arranged and configured such that said interface member can be disposed against the outer surface of the door jamb assembly and can extend over, and overlie, at least a portion of the outer surface of the door jamb assembly, the outer leg section further comprising a resiliently cushioning nose member extending outwardly in front of the interface member, a cavity being optionally defined between the interface member and the resiliently cushioning nose member.
In some embodiments, the nose member defines an arcuate cross-section, thereby to transfer substantially all low-to-medium intensity forces, imposed on the nose member, to the interface member proximate the central section and proximate a distal edge of the interface member.
In preferred embodiments, the guard can be installed on a doorjamb assembly, and a conventional door mounted to the door jamb assembly can be closed with the guard so installed, without interfering with operation of the door.
In some embodiments, the guard is designed and configured to fit over and protect at least part of an outer trim element as part of the door jamb assembly.
In some embodiments, the door leg section has a first length between the central section and an opposing distal edge of the door leg section, the outer leg having a second length, substantially greater than the first length, between the second side of the central section and an opposing distal edge of the outer leg section.
In a fifth family of embodiments, the invention comprehends, in combination, a door jamb assembly, and a removable guard mounted over and overlying at least a portion of the door jamb assembly. The combination comprises the door jamb assembly having an inner-facing surface for facing into a door opening, a door-arresting surface, and an outer surface for facing away from the door-arresting surface, the inner-facing surface extending from the door-arresting surface to the outer surface; the removable guard protecting the door jamb assembly from incidental damage. The guard comprises a central section overlying the inner-facing surface of the door jamb assembly, the central section having a first door side, and a second opposing side displaced from the door side, a door leg section, connected to the central section at the first door side, and an outer leg section, directly or indirectly connected to the central section at the second side, displaced from the door opening, the outer leg section extending at a transverse angle to the central section, the outer leg section being disposed against, and protecting, the outer surface of the door jamb assembly.
In preferred embodiments, the guard overlies and protects a brick mold, a mull post, or other trim element, as part of the door jamb assembly.
In preferred embodiments, the combination includes weather stripping adjacent the door-arresting surface, and the door leg section is disposed between the door-arresting surface and the weather stripping, without interfering with routine mounting, or routine operation, of the weather stripping.
In a sixth family of embodiments, the invention comprehends a method of protecting a doorjamb assembly which may be mounted in a doorway and controlling access to a building through the doorway opening, thus protecting the jamb assembly from incidental damage during a period when the door jamb assembly is susceptible to an elevated level of risk of damage. The door jamb assembly comprises left and right upstanding jamb assembly elements, and optionally an upper jamb assembly element extending between the left and right upstanding jamb assembly elements. Each such jamb assembly element has an inner-facing surface facing into such doorway opening, a door-arresting surface, and an outer surface facing away from the door-arresting surface, the inner facing surface extending from the door-arresting surface to the outer surface. The method comprises installing, on one or more of the jamb assembly elements, a removable jamb assembly guard, the jamb assembly guard comprising a central section which overlies the inner-facing surface of the door jamb assembly, and which has a first door side, and a second opposing side displaced from the door side, a door leg section, connected to the central section at the first door side and extending at a transverse angle to the central section along the door-arresting surface of the door jamb assembly, and an outer leg section, connected directly or indirectly to the central section at the second side displaced from the doorway opening, the outer leg section extending at a transverse angle to the central section. The outer leg section of the guard is thus disposed against the outer surface of the door jamb assembly such that the outer leg section extends over, and overlies, at least a portion of the outer surface of the door jamb assembly. The jamb assembly guard, when installed on the door jamb assembly, has the central section thereof overlying the inner-facing surface of the door jamb assembly, the outer leg section overlying and protecting at least a portion of the outer surface of the door jamb assembly, and the door leg section extending across and protecting the door-arresting surface.
In preferred embodiments, the guard is mounted and held to the jamb assembly by friction and/or temporary tab interaction with the jamb assembly.
In some embodiments, the method includes installing the guard on the jamb assembly in combination with a door slab being installed on the jamb assembly, and including closing the door slab, thus to close the door opening, with the guard so installed and without interference between operation of the door slab and the guard.
In some embodiments, the jamb assembly includes an outer trim element disposed outwardly from the door opening, the method including installing the guard so as to protect at least part of an outwardly-facing surface of the outer trim element.
In some embodiments, the central section comprises inner and outer section elements, for interlocking with each other thereby to establish an adjusted width of the central section, the method comprising placing the guard over the jamb assembly with the central section in surface-to-surface contact with the inner-facing surface of the jamb assembly, the outer leg section being disposed relatively outwardly of the doorway opening, the door leg section being disposed at the door-arresting surface, the method further comprising urging the inner and outer sections toward each other, thus slidingly engaging the inner and outer sections with each other and causing the inner and outer sections to grippingly engage the door-arresting surface of the jamb assembly and the outer surface of the jamb assembly, thus to custom adjust the guard to the respective jamb assembly.
In some embodiments, the central section can comprise a line of weakness extending along the length of the central section, wherein the line of weakness facilitates separating the guard into inner and outer separate sections, as by tearing or breaking at the line of weakness. The method of installing the guard includes tearing or breaking the guard at the line of weakness, then overlapping the separated inner and outer guard pieces with respect to each other at the central section, to fit the thickness of the jamb assembly, then securing the inner and outer pieces to each other, at the central section, to maintain the fitted thickness. The overlapped pieces can be secured to each other as by applying tape at the so-defined overlapped joint. In the alternative, one or more pieces of tape can be supplied on the central section, with a release sheet. When the central section is broken, the release sheet is removed, whereby the tape is exposed for securing the pieces to each other when the inner and outer sections are brought together in overlapping relationship.
In preferred embodiments, the method includes removing the guard from the jamb assembly when the period of elevated risk has ended.
The invention is not limited in its application to the details of construction or the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Also, it is to be understood that the terminology and phraseology employed herein is for purpose of description and illustration and should not be regarded as limiting. Like reference numerals are used to indicate like components.
In the embodiments disclosed herein, door jamb assemblies are shown oriented such that the door, also referred to herein as a “door slab,” opens inwardly into the building or room or suite being serviced by the door. The principles of the invention apply equally where the door opens in an outwardly direction, with allowance for additional necessary clearance factors.
Jamb 16 can be made of a variety of materials. A typical such material is wood. Another commonly used jamb structure employs wood as a substrate, cladded with, for example, cladding “CL”(
A typical jamb assembly 10 includes the jamb 16 which has an inner-facing central surface 22, a door-arresting surface 24 (
A weather strip or weather seal 28 is shown in
As illustrated in
Door leg section 46 of guard 36, as enumerated in
An outer leg section 52 of guard 36 is connected to central section 40 of the guard at opposing trim side 44 of the central section, and extends transverse, e.g. perpendicular, to the central section, over a portion of trim element 18, thereby to protect outer corner 54 of the trim element.
It is well known that the most vulnerable, the most commonly damaged elements of the jamb assembly, are outer corner 54 of the trim element, and corresponding outer corner 55 of the jamb.
Outer corner 56 of the guard illustrated in
Still referring to guard 36, friction tabs 60 are mounted on both door leg section 46 and outer leg section 52. A friction tab 60 can be configured as a strip of material extending, either continuously or intermittently, along the length of the respective section of the guard.
Tabs 60 can be applied by a variety of methods. For example, tabs 60 can be adhesively mounted, e.g. contact adhesive, to the guard. Preferably, tabs 60 are melt-applied to the guard, such as, for example and without limitation, using hot melt adhesive, coextrusion, or extrusion coating. Friction tabs 60 can be employed elsewhere on the guard, as desired.
Tabs 60 can be for example and without limitation, adhesive tape using a substrate having a relatively high friction surface. As suitable such materials, there can be mentioned e.g. various rubbers and other polymeric materials, such as polyolefins, vinyl acetates, vinyl chlorides, and the like, including suitable additives such as plasticizers and/or tackifiers.
The surface of tab 60 which interfaces with e.g. jamb 16 or brick mold 18 can have a wide variety of configurations. Thus, the surface can be substantially solid, namely unbroken, as shown in the drawings, or can be more of a textured surface. Exemplary textures include, without limitation, male or female dimples, parallel or non-parallel ridges including random ridges, teeth, or the like, or one or more fingers as illustrated in
A tab 60 can comprise a relatively less flexible or less compressible substrate disposed toward leg section 46, and a relatively more flexible or more compressible action layer, having such dimples, ridges, or teeth, in interactive contact with e.g. jamb 16 or brick mold 18.
Guard 36 is typically installed as 3 elements, namely a left upstanding element, a right upstanding element, and a top element extending between the left and right upstanding elements and covering the top element of the jamb. Accordingly, the three elements of the guard cover substantially the entire external profile or surface of jamb 16, and especially that portion of the jamb profile between the door-arresting surface, and the outer surface of the jamb assembly at outer surface 38 of trim element 18. The three elements can, as desired, be hinged to each other with e.g. plastic hinges whereby guard 36 can be a unitary article.
Outer leg section 52 of nose element 68 includes an interface member 76 which interfaces with trim element 18, and a cushioning nose member 78 which extends outwardly in front of the interface member, and in front of the trim element. A cavity 80 is defined between interface member 76 and nose member 78. Especially nose member 78 is resiliently deflectable, while having substantial bending resistance to forces imposed thereon, thus to transfer substantially all low-to-medium intensity loads such as impacts, imposed on the nose member, to the interface member proximate central section 40 of the guard and proximate distal edge 64 of interface member 76, thus away from outer corner 54 (
Further comparing
Still referring to
Yet further referring to
Another feature of the arcuate nature of outer leg 52 is that, when a modest force is applied to the arcuate leg section, directed toward the brick mold, inward movement of the outer leg section automatically rotates cover tab 92 away from outer face 94 of the brick mold. Such flexing of the outer leg section can thus be employed to facilitate mounting the guard to the jamb assembly, and corresponding dismounting of the guard when the guard is desirably removed from the jamb assembly.
As suggested by the structure of
In general, as depicted in
Guard 436 differs from guard 336 in that guard 446 includes a breakable line of weakness 100 at the intersection of distal end 88 of outer leg section 52 with tab 92. Given the full coverage of the outer surface of brick mold 18 by outer leg section 52, supplemented by tab 92, the guard, as initially installed over the jamb assembly protects the entirety of the brick mold outer face 38 from external forces exerted against the jamb assembly. However, as desired for facilitating ongoing progress in completing the construction project in the vicinity of the door, tab 92 can be broken off by the construction workers. For example, where the outer surface of the building extends outwardly from brick mold 18, tab 92 interferes with installation of such outwardly-extending material. Thus, where an outer surface of e.g. brick or stone is used outwardly of e.g. sheathing 34, the brick or stone typically extends outwardly past the brick mold. Accordingly, by structuring guard 436 with breakable line of weakness 100, tab 92 can be removed thus to facilitate installation of the brick or stone, without interfering with continued use of guard 436 to protect the remaining portions of the jamb assembly.
Guard 436 further includes a flex joint 102 in outer leg section 52. Flex joint 102 enables the outer leg section to flex at a predictable location under low load force, thus to facilitate installation of the guard. Joint 102 is also used to move tab 92 out of the way to facilitate installation of thinner section siding materials such as lap siding. Typical such sidings are, without limitation, vinyl siding, aluminum siding, or steel siding. Thus, when it is time to install the siding, the outer leg section is flexed at joint 102, rotating that portion of the outer leg section, distal from the joint, away from the brick mold as suggested by arrow 103. The angle of rotation about joint 102 is as desired by the workers doing the work, and can be any angle which can disable any effective hindrance imposed by outer leg section 52 or tab 92. Tab 92 also moves with the rotating portion of the outer leg section. The tab, and the distal portion of the outer leg section, are held so rotated until such time as installation of the siding has been completed in the vicinity of the door opening. Once siding installation proximate the door opening, and other related work, has been completed, the outer leg section portion, and tab 92, are rotated back into facing relationship with brick mold 18 generally in accord with the orientation shown in
The outer leg section generally follows the outline of outer face 38 of the brick mold. As in
Details of the embodiments of
As an illustration of an operable line of weakness 100, thickness of the guard at the line of weakness is about half the thickness of the guard away from, but proximate, the line of weakness. In general, a line of weakness thickness “T” of about 0.015 inch to about 0.030 inch is preferred, with a highly preferred line of weakness thickness being about 0.020 inch with preferred materials. Effective thickness ranges of the line of weakness depend on materials selections, and structure of the line of weakness, whereby thicknesses outside the recited ranges are contemplated where the material selection, and/or structure of the line of weakness, so dictate or suggest.
If no transfer web is used, the location of line of weakness 101 can be selected still further toward outer leg section 52. As with line of weakness 100, the thickness of the guard at line of weakness 101 is about half the thickness of the guard at locations away from, but proximate, the line of weakness. In general, a line of weakness thickness “T2” of about 0.015 inch to about 0.030 inch is preferred, with a highly preferred line of weakness thickness being about 0.020 inch. As with line of weakness 100, effective thickness ranges of line of weakness 101 depend on materials selection, as well as structure of the line of weakness, whereby thicknesses outside the recited ranges are contemplated where the material selection so dictates.
Either of lines of weakness 100 and 101 can be continuous or discontinuous. While a groove structure is shown, a wide range of structures are known for use as lines of weakness, and all such known structures are contemplated herein to the extent such structures operate in the manner discussed herein.
Comparison of
In installing a properly sized guard on a door jamb and brick mold or other trim, the angles are necessarily enlarged, especially angles “A2” and “A3”, to accommodate the perpendicularity of the surfaces of the jamb and brick mold with respect to each other. Especially angles “A2” and “A3” are about 80 degrees to about 86 degrees in order that the installed guard firmly grips the jamb and brick mold, with friction fit.
Thus, the guard is resiliently stressed by the expansion of angle “A3” as the transfer web is stressed, and by the expansion of angle “A2” between the central section and the door leg section, and where used, by the expansion of angle “A5” between the outer leg section and the cover tab. Thus, a potential energy gripping force is imparted to the guard in the process of installing the guard on a jamb assembly.
Use of line of weakness 101 is illustrated in
When a non-standard jamb assembly is to be protected, a standard-size guard is selected, namely the first standard size which, at the central section, is larger than the central section of the jamb assembly which is to be protected. Prior to installing the guard, the guard is broken/torn at line of weakness 101 so as to separate the outer piece 360UT from the inner piece 36IN. The pieces 360UT and 36IN are then mounted over the jamb assembly, with the broken/torn edges overlapping each other as illustrated in
With the guard thus mounted on the jamb as shown in
Tape 120 can be continuous along the full length of the broken line of weakness. In the alternative, pieces of tape can be installed at spaced intervals along the length of the broken line of weakness. For example, on a guard 36 protecting a left or right upstanding jamb assembly, in a typical personnel door, four strips of tape might be used, each strip being e.g. 4 inches (10.2 cm) long. A lesser or greater number of pieces of tape can be used. And the pieces can be longer or shorter than the exemplary 4 inches (10.2 cm). Indeed, any amount of tape can be used so long as the tape is at least effective to sufficiently affix the inner and outer guard pieces to each other.
Tape 120 can be any tape which has suitable adhesion to the material used at central section 40 of the guard, and which has suitable strength of tape substrate, to withstand, tolerate, the forces typically expected to be imposed on guard 36. In addition, tape 120 should have limited extensibility whereby the tape controls movement between the respective inner and outer guard pieces in response to forces which tend to expand the width of the tape across the joint between the overlapping inner and outer pieces of the guard.
While the tape can be any desired width, a typical width is about 2 inches. Examples of commonly available tape 120 are commonly known as duct tape, and certain packaging tapes which meet the strength, and limited extensibility, requirements.
The location of line of weakness 101 can be anywhere between door leg section 46 and outer leg section 52, so long as the location of the separation accommodates the separated edges lying in overlying, underlying relationship with each other without interfering with the guard effectively gripping the jamb assembly.
As referred to herein, the “outer leg section” is that portion of the guard which overlies the outer face 38 of the brick mold.
As referred to herein, the “central section” is that portion of the guard which overlies the inner facing surface 22 of the jamb.
As referred to herein, the “transition section” is that portion of the guard defined between the central section and the outer leg section, and which generally bridges across the open space between corners 54 and 55 of the jamb assembly.
As an overview of the embodiments illustrated, it is seen that each guard has at least some form of contact structure, and preferably a transition section having force-transferring support structure, proximate the most vulnerable areas of the jamb assembly, namely proximate outer corners 54 and 55. In
As a general statement, transition section 82 is an overlying contact structure which directly interfaces with objects which impact on the transition element at or adjacent the corners 54, 55 of the jamb and the trim element. The transition section typically includes underlying support structure adapted and configured to interface with one or more underlying surfaces of the jamb and/or trim element. The transition element is thus the portion of the guard which receives the greatest fraction of the impacts on the guard, and is accordingly designed as a shock absorber, to absorb and distribute the impacts/forces imposed thereon, e.g. from objects passing through the doorway, so as to prevent, or at least substantially attenuate, damage to the jamb assembly.
In view of the wide variety of exemplary transition sections illustrated, it is clear that other equivalent transition sections can be developed, which will function generally in the manner described herein to transfer e.g. impact forces away from outer corners 54 and 55, and to dissipate such forces so as to substantially reduce the amount of damage typically experienced at doorways during a given type of use of the respective doorway.
The material selected for making guard 36, including contact web 83, should be sufficiently durable to withstand expected levels of impact, while having sufficient cushioning effect to protect the jamb assembly from incidental collisions of the nature typically encountered in doorways at a construction site. As typical materials, there can be mentioned a number of plastic compositions such as, for example and without limitation, various of the polyolefins such as and without limitation, high density polyethylene, polypropylene, polyvinyl chloride, polyamide, polyester, and the like. In addition, guard 36 can be made from an expanded foam material such as, for example and without limitation, foamed polyethylene, foamed polypropylene, or foamed polystyrene. Where desired, guard 36 can comprise multiple layers extending over some or all of the length and width of the guard. In such polymeric compositions, typical additives such as slip, release, and like materials can be employed as desired by those skilled in the art.
While a number of polymeric materials have been recited above as materials suitable for making the guard, any of a wide variety of materials, susceptible to fabrication in thin cross-section, can be employed. As other materials, there can be mentioned, for example and without limitation, various metals, heavy paperboard, multiple layer paper and paperboard including products incorporating corrugated media therein, pulp-molded sections, and the like.
Friction tabs 60 can be continuous or discontinuous along the length of the guard. A friction tab 60 can be configured as a strip of material extending along the length of the respective section of the guard. Tabs 60 can be applied by a variety of methods. For example, tabs 60 can be adhesively mounted, e.g. by contact adhesive, such as a double-sided tape, to the guard. Tabs 60 are preferably melt-applied to the guard such as, for example and without limitation, using hot melt adhesives, coextrusion, or extrusion coating processes.
The combination of materials selection, cross-section configuration, and length and width of guard 36, preferably enable resilient flexing of guard 36 toward and away from jamb assembly 10. For example, transfer web 86B and door leg section 46 can be flexed away from the jamb to facilitate mounting the guard to the jamb assembly. As the flexing force is withdrawn, the guard comes into gripping engagement with the jamb assembly as the resilient forces in the guard structure restore the guard toward the rest configuration. Preferably, the inner surface of the guard comes into gripping contact with the outer surface of the jamb assembly before the guard is fully restored to its rest configuration, whereby the resilient forces in the guard assist in retaining the guard securely mounted to the jamb assembly.
Now referring to all the illustrated embodiments, in those preferred embodiments of the invention where guard 36 does not extend substantially inwardly beyond door-arresting surface 24, the guard plays no role in determining the clearance between the door slab and the jamb assembly as the door swings toward door-arresting surface 24. Thus, in such embodiments, the thickness of the guard is not limited by any definition of the swing clearance between the door slab and the jamb assembly. Accordingly, and in such embodiments, guard 36 can be as thick as desired in order to provide the desired level of protective cushioning to the underlying jamb assembly, without considering clearance between the door slab and the jamb assembly. Thus, thickness of the guard can be as little as e.g. about 0.03 inch, and up to any thickness desired, for example up to about 0.25 inch. However, for purposes of economy, and for cost effective performance, while effectively protecting the jamb and brick mold, thickness is typically of the order of about 0.035 inch to about 0.06 inch.
In some embodiments, not shown, guard 36 can include an inwardly-disposed element which extends from door-arresting surface 24 inwardly along inner-facing surface 22 of jamb 16 to an inner surface 118 of the jamb. For an exterior door, the inwardly-disposed element is separate and distinct from the guard 36 as shown, in order to not overlie weather strip 28. For interior doors, where no weather strip is used, the inwardly-disposed element can be an integral part of guard 36. In either event, the inwardly-disposed element does co-occupy jamb space in close proximity with the door slab when the door is closed against the door-arresting surface. Accordingly, the inwardly-disposed element is necessarily thin, e.g. no more than about 0.020 inch thick, in order to facilitate acceptable clearance between the door slab and such inwardly-disposed element.
In the alternative, such inwardly-disposed element can extend less than the full distance to door-arresting surface 46, and can be spaced from the door arresting surface by a distance sufficient to preclude any interference between the guard element and the distal edge of the door slab as the door slab is opened and closed on the doorway opening. Since the uncovered space is located near the door-arresting surface; since the edges of surface 118 are protected, the risk of damage to the jamb is small while the thickness of the inwardly-disposed element can be selected while focusing on protection properties without substantial concern for clearance from the edge of the swinging door slab.
Overall, the guard 36 is resiliently flexible, with rest angles, in some embodiments, between the central section and the outer leg section, and between the central section and the door leg section, of moderately less than 90 degrees, as known in the art, e.g. about 80 degrees to about 88 degrees, so as to exert a degree of resilient restorative force on the jamb assembly, thereby to assist in gripping the jamb assembly when the guard is so installed. Where cover tab 92 is used, the cover tab further, or in the alternative, assists in such gripping.
Guard 36 can be made as a continuous, single-piece plastic extrusion, cut to length, and having a profile as illustrated in e.g. the respective cross-section figures, optionally having lines of weakness 100 and/or 101. In the alternative, the guard can be made as multiple extrusions which are joined together when being installed on the door jamb assembly as illustrated in
The method of fabricating guard 36 will be readily selected by those skilled in the art, from known fabrication methods, once the material, from which the guard is to be made, has been selected. Plastic extrusion is a highly preferred method of fabricating guards 36.
As used herein, the phrase “jamb assembly” collectively refers to, in a first event, a door jamb with which a door slab interfaces, and in a second event also refers to the outer trim element illustrated as brick mold 18, which may be joined to the jamb at the outer surface of the doorway.
Guard 36 is used as follows. Once the jamb assembly has been installed on the building in the rough opening, and either before or after the door slab has been installed in the opening defined by the jamb assembly, guard elements are brought into facing relationship with respective upright and/or top elements of the jamb assembly. Thus, a left guard element having a length approximating the height of the left jamb assembly element is brought into facing relationship with the left jamb assembly element.
The left guard element is urged over the left jamb assembly element, with resilient deflecting of the guard element as the guard element is urged into place, with the door leg section at the door-arresting surface, preferably under any weather stripping; and with the outer leg section overlying at least a portion, preferably all, of outer face 38 of the trim element. Friction tabs 60, in combination with the restorative force inherent in the material of the guard element, the angular deflection from the near perpendicular angles of the leg sections, and friction between the guard and the jamb assembly, all work together to assist in retaining the guard on the jamb assembly.
The right and top guard elements are similarly installed, as desired, such that a major portion, preferably substantially the entirety, of the exposed surface of the jamb assembly, disposed outwardly, in a direction away from the building, of the door-arresting surface, is covered by the guard, as illustrated in the respective cross-sections in the drawings. In those embodiments which employ inwardly disposed elements of guard 36, the guard can also cover the portions of the jamb assembly which are disposed inwardly of the door-arresting surface.
In the preferred embodiments, wherein the guard does not extend inwardly into the building or room or suite, from the door-arresting surface, or where an inwardly-disposed element of the guard is spaced from the door arresting surface, the guard does not interfere with swing of door slab 30 as the door slab is being closed toward door-arresting surface 24, whereby the door slab can be closed on the opening defined in the doorway while the guard is installed about the door jamb assembly, without the guard interfering with swing of the door slab. Accordingly, the door slab can be closed, and optionally locked, thus to deny or otherwise control access to the construction project area in the building while the guard is installed on the jamb assembly.
Thus, the guard can be installed on the jamb assembly as soon as the jamb assembly is constructed, including before the jamb assembly is installed in the door opening, and can remain continuously installed on the jamb assembly while the jamb assembly is being shipped in commerce, while the jamb assembly is being installed in a doorway opening, and throughout the term of the construction or other elevated-risk project, including periods when the door slab is closed and locked, without in any way affecting closing of the door. Accordingly, once guards of the invention are installed on a jamb assembly, such guards can be left installed until such time as the project is substantially completed and danger of damage to the jamb assembly has substantially passed. Such installation of the guard can be done at the jamb assembly manufacturing site, prior to shipping in commerce, whereby the jamb assembly guard serves as a shipping protector, as well as serving as a guard when the jamb assembly is mounted in the doorway of a building.
Flex joint 102, illustrated in
For guards which employ a flex joint 102 as illustrated in
Apertures, not shown, can be spaced along the length of the central section 40 extending the thickness of the guard. Such apertures are of sufficient size and configuration to serve as access loci to facilitate driving fasteners, e.g. nails or screws, through jamb 16 and into studs 14, thus to secure jamb 16 to the building. In such implementation, the fasteners do not interact with guard 36 in such manner as to impede subsequent removal of the guard from the jamb assembly e.g. when the construction project has been completed.
Once the period of elevated risk of damage to the jamb assembly has passed, or has been substantially alleviated, the guards can be removed, again with resilient deflection of the guards, and/or with deflection of outer leg section 52 and/or cover tab 92, whereupon the jamb assembly, as covered by the guards, should be free of collision-imposed defects. At minimum, the incidence, and level of severity, of affect on the jamb assembly, is substantially reduced as a result of having used guard 36 to protect the jamb assembly. The temporary door slab is typically, at the same time, replaced with the permanent door slab, whereupon the doorway can be released to custody of the owner or occupant of the building in good condition, in spite of typical construction-related impacts, associated with the e.g. construction project, which may have been imposed on the doorway during the pendency of the construction project.
As used herein, the phrase “inner-facing surface” of the jamb assembly refers primarily to the inner facing surface 22 of the jamb, but also and as appropriate, refers to surface 96 of the brick mold. Thus, to the extent the inner facing surface of the trim element is displaced from the inner facing surface of the jamb, as in the illustrated embodiments, the inner facing surface of the jamb assembly can be discontinuous with respect to a step change at the trim element.
Those skilled in the art will now see that certain modifications can be made to the apparatus and methods herein disclosed with respect to the illustrated embodiments, without departing from the spirit of the instant invention. And while the invention has been described above with respect to the preferred embodiments, it will be understood that the invention is adapted to numerous rearrangements, modifications, and alterations, and all such arrangements, modifications, and alterations are intended to be within the scope of the appended claims.
To the extent the following claims use means plus function language, it is not meant to include there, or in the instant specification, anything not structurally equivalent to what is shown in the embodiments disclosed in the specification.
This application claims priority under 35 U.S.C. 119(e)(1) to Provisional Application Ser. No. 60/394,811 filed Jul. 9, 2002, and to Provisional Application Ser. No. 60/403,955, filed Aug. 16, 2002, both of which are herein incorporated by reference in their entireties.
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| Number | Date | Country | |
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| 20040006938 A1 | Jan 2004 | US |
| Number | Date | Country | |
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| 60403955 | Aug 2002 | US | |
| 60394811 | Jul 2002 | US |
