Patent Grant
7661226
The present invention relates generally to a storm door. More particularly, the present invention relates to methods and apparatuses for an easy installation pre-assembled storm door.
For many years storm doors have been produced and utilized to provide an extra measure of thermal insulation and weather protection at door openings of a building. Storm doors are currently formed of one or more panes of glass seated within a surrounding doorframe. Storm doors may include panes that are movable within the door, or may be provided with a removable window pane that may be replaced with a screen to provide ventilation. Storm doors may be installed on a building or home long after the initial building construction. In many cases a homeowner who is not an expert in construction installs storm doors. The storm doors installed by the homeowner may be a custom manufactured door or may be a generic one-size-fits-all type door that is mass produced. Ease of installation is an obvious benefit for storm doors installed by the layman homeowner, as well as for professional installers desiring to minimize the time spent at a jobsite.
Easy install storm doors are often pre-assembled and pre-hung at the factory where they are manufactured. Factory assembled pre-hung doors normally include a door secured by hinges to a surrounding frame. The factory-assembled units may be mounted for opening in either a right or left hand direction. Other door and doorframe combinations may come in an unassembled condition wherein few or no holes are pre-drilled and various parts must be cut to size. In such combinations the installer may be required to drill many holes in the door and in the frame and to cut the door, frame, or other portions to insure the proper fit. This arrangement requires the user to have a certain degree of skill to mount the door. Moreover, installation of these door combinations may take many hours of work for the average layman without the help of a skilled installation expert.
The present invention is a pre-assembled door system for easy installation that can be installed in a right hinge or left hinge manner while utilizing the same locking assembly.
One embodiment of the present invention is furthermore a method of installing a door system pre-mounted to a vertical z-bar.
Another embodiment of the present invention is an express install kit for installing a storm door in a doorframe including a door panel for insertion into the doorframe in either a right hinge or a left hinge orientation, a hinge z-bar and a latch z-bar, the hinge z-bar pivotally mounted to a first side of the door panel and the latch z-bar removably secured to a second side of the door panel, the hinge z-bar allowing the door panel to open in one direction in relation to one side of the door panel, the hinge and latch z-bars being fixedly securable to the doorframe, a lockbody installed in the door panel, the lockbody including duplicate lock hardware receiving structures such that the door panel can be situated in the doorframe in the right hinge or the left hinge orientation, and one or more door closing assemblies, the closing assemblies including jamb bracket bases, jamb brackets, door brackets, and closers, the jamb bracket bases mountable onto the doorframe in a guided position by aligning a guide indicia on the jamb bracket base with an indicator on the door panel and z-bar, the jamb brackets securable to the jamb bracket bases, the door bracket securable to the door panel, and the closers linking the jamb brackets and the door brackets with a desired amount of tension.
Another embodiment includes a door closer assembly for a storm door with a jamb bracket base, the jamb bracket base mountable onto a doorframe surrounding the storm door in a guided position by aligning a guide indicia on the jamb bracket base with an indicator on the storm door and a door closer of variable length with an installation length predetermined and preset at the factory, the door closer secured between the jamb bracket base and the storm door whereby when the storm door is in a closed position the door closer is at the installation length.
Yet another aspect of the invention includes a lockbody for a pre-assembled storm door comprising a lockbody installed in the storm door, the lockbody including duplicate lock hardware receiving structures situated in a mirror format across a horizontal plane, the lockbody placed into the pre-assembly storm door whereby the door panel can be situated in a doorframe in a right hinge or a left hinge orientation.
Another embodiment includes a method for installing a door into a doorframe including providing a door panel with an external surface, a hinge z-bar, and a latch z-bar, the hinge z-bar pivotally mounted to a first side of the door panel and the latch z-bar removably secured to a second side of the door panel, orienting the door panel for either a right hinge or a left hinge operation so that the external surface faces an external side of the door frame, attaching a bottom expander to a bottom side of the door panel, the bottom expander attachable in a selected position on the door panel, the bottom expander including a bottom spacer for insuring a correct spacing between the door panel and the bottom of the doorframe, setting the door panel in the doorframe and securing the hinge z-bar and the latch z-bar to the doorframe such that the door panel is free to swing between a closed position and an open position, securing a top mounting frame to the top of the doorframe, the top mounting frame extending between the door panel and the doorframe, the top mounting frame including a spacer for insuring the top mounting frame is properly positioned relative to the door panel, inserting a key cylinder into one of two symmetrical lock hardware receiving structures on a mortise lockbody mounted in the door panel, aligning one or more jamb bracket bases onto the doorframe in a desired position by matching a guide indicia on the jamb bases, mounting one or more closers to each jamb bracket base and attaching the closers to the door panel, the closers being of variable length but releasably secured at an installation length; releasing the one or more closers, and adjusting the position of the bottom expander relative to the doorframe to lightly contact the bottom side of the doorframe.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
The present invention is a pre-assembled door system 50 for quick and easy installation. While it is recommended that two or more people install door system 50 for safety reasons, the total installation may be accomplished by one person of reasonable competency in one hour or less. Moreover, the installation of the door system 50 may be accomplished with a minimum of tools and a minimum of cutting, drilling, etc. The door system 50 described below is for a storm door, but, as may be appreciated, this invention is not strictly limited to storm doors. Other types of doors and windows may also be included within the teachings of the present invention.
The door system 50 of the present invention includes a storm door 52 that is pre-assembled as opposed to pre-hung. The orientation in the left hand or right hand is not selected until the time of installation. On a pre-hung door the jambs and header are part of the door assembly. The present invention door system 50 does not require the user installing the storm door 52 to drill into or cut off any portion of the storm door 52 as provided. The only holes that need to be drilled by the installer may be pilot holes in a doorframe of the building.
The present invention description is put forth in view of installing the storm door 52 in a house 54. As illustrated in
As illustrated in
With reference to the enclosed figures, the components of the present invention will first be described. Afterwards, a description of installing the door system 50 in view of utilizing these components will be put forth. As may be appreciated, the door system 50 may include a number of alternative and/or additional components. Moreover, each component can be a number of different sizes or shapes and may be attached in a number of different ways, including screws, pins, nails, friction fittings, etc. The present embodiment is therefore described in view of the embodiment illustrated in the drawings and described with an eye towards the function of each component rather than just the strict size and shape of each component or how each component is fastened in position. Moreover, the purpose for each component of the door system 50 may not be immediately and readily apparent until the component is discussed or referred to in terms of installing the door system.
The Door System Components
The door system 50 may come packaged together in one box for easy shipping. Such a door system may be referred to as a “kit” or a “door kit.” The door kit is illustrated in
The door panel 66 may be the main body of the storm door 52 (minus the glass or screen) and will be referred to herein as a “door panel” to differentiate clearly between the various items with “door” in the name and the completed storm door 52 that includes many of the other components of door system 50. The door panel 66 included in the door system 50 may be a door of conventional construction and may be of any standard size. The size of the existing doorframe 56 may determine the size of the door panel 66 that needs to be installed therein. Different door systems 50 may include door panels 66 with different dimensions.
The door panel 66 may be any type of door panel known to those in the art, such as including four piece, one piece, extruded hollow, laminated, molded, or an arch top. The door panel 66 includes a latch side 86, a hinge side 88, a top side 90, and a bottom side 92. The latch side 86 of the door panel 66 may include the lock assembly 80 mounted therein and a series of cutouts 94 that expose and give access to the lock assembly 80. The hinge side 88 and the latch side 86 may both include a hinge z-bar 96 and a latch z-bar 98, respectively. As may be appreciated, the “top” and “bottom” of the door panel 66 may be switched depending on whether a right hinge or left hinge installation is selected.
As illustrated in
The latch z-bar 98 may also include a shipping plate 97 illustrated in
As shown in
As illustrated in
As illustrated in
The bottom expander 72 may also include a bottom spacer 120. The bottom spacer 120 may be a generally U-shaped body designed to fit over the bottom expander 72. The bottom spacer 120 may be of a size and shape to be connected over the bottom expander 72 with the flanges engaging the bottom surface 114 of the bottom expander 72. The bottom spacer 120 may be snapped over the bottom expander 72 by friction fitting but may, in alternative embodiments, be secured to the bottom expander 72 by screws, snaps, etc.
As illustrated in
As is further illustrated in
As shown in
In addition, each jamb bracket base may include an alignment tab 146. The alignment tab 146 may be of a predetermined size and shape so as to help correctly position each jamb bracket base 128, 130 relative to hinge z-bar 96, and in turn door panel 66, during installation. The jamb brackets 132, 134 may each include a base 150 and a head 152. The base 150 includes a hollow interior cavity 148 for receiving the slide connectors 142 of the jamb bracket base 128, 130. The head 150 may be generally shaped in an arch and include a pin receiving hole 154. The jamb bracket base 128, 130 may also include a tongue 131. The tongue 131 lockingly secures the top and bottom jamb bracket 132, 134 to the corresponding jamb bracket base 128, 130. However, the tongue 131 can be depressed to easily remove the jamb bracket base 128, 130 and therefore the entire top and bottom closure assembly 82, 84. This may be particularly useful when moving large objects through the door system 50 and the storm door needs to be opened to its fullest extent.
The top and bottom door brackets 136, 138 may include a number of pre-drilled holes for securing the door brackets 136, 138 to the door panel 66 and also a pin means for securing the door brackets 136, 138 to the top and bottom closers 124, 126.
In the present embodiment the top and bottom jamb brackets 132, 134 may already be pivotally secured to the top and bottom closers 124, 126, respectively. The top and bottom closers 124, 126 may each include a shaft 156 that extends longitudinally from the closer. The shaft 156 may be secured to the top and bottom jamb brackets 132, 134 in a pivotal orientation. The function of the shaft 156 may be well known in the art. The top and bottom closers 124, 126 may also include a clip 135 on the shaft to maintain the closer 124, 126 at a desired installation length until after the closers 124, 126 are installed. The installation length may be predetermined at the factory such that it will create the proper tension to properly and completely shut the door panel. As may be appreciated, the clip 135 may be replaced with any type of pin, snap, bracket, o-ring, snap ring, etc. Such a pre-assembled top and bottom closer 124, 126 may aid in quick installation of door system 50.
The various portions of the door system 50 may be made of any suitable material. In many cases, pieces such as the hinge and latch z-bars 96, 98 may be made of extruded metal. In addition, other pieces may be made of forged metal, plastics, high density plastics, wood, etc. The door panel 66 may include portions made of wood, aluminum, steel, fiberglass, plastic, and other suitable materials.
As illustrated in
The interior and exterior escutcheons 164, 168 may be the faceplates of the lock assembly 80 below the handles 162, 170 and may be any desired ornamental configuration. The spindle 166 may be a longitudinal shaft of a certain shape designed to engage the first and second handle 162, 170 so as to rotate in unison. The key cylinder 160 may be the body that controls the extension and retraction of the dead bolt 174 and may include a first end into which a key may be inserted and a second end with a thumb latch 181. The spindle 166 is normally square shaped when viewed from one end and fits through the spindle receiving lumen 176 that is specifically shaped and sized to receive the spindle 166. The operation of the spindle 166 and spindle receiving lumen 176 to move the latch bolt 172 when activated by the first or second handles 162, 170 may be well known to one skilled in the art. In the present embodiment, the spindle receiving lumen 176 may be positioned on the opposite side of the latch bolt 172 from the corresponding key cylinder 160 first end. In the present embodiment lock assembly 80 the latch bolt 172 may be retracted to open and close the door by simply turning the first or second handle 162, 170. The deadbolt 174 may be that portion of the lock assembly 80 that can be engaged into a locked position.
The lock assembly 80 may further include a trim plate 182 that may be secured to the latch z-bar 98. As illustrated in
The interior mechanism of the lock assembly 80 is illustrated in
In addition, both dead bolts 174 may be extended or retracted by action of key cylinder 160 no matter in which key cylinder receiving member 178 the key cylinder 160 is placed. The dead bolts 174 may extend and retract in unison by action of two slides 192 and a beam 196. When the key cylinder 160 is rotated by the thumb screw 181, for example, the nearest dead bolt 174 may be extended or retracted by direction action of the key cylinder 160. The extension or retraction of the dead bolt 174 causes the corresponding slide 192 to move in a track 193 in the beam 196. The movement of the slide 192 in the track 193 through which the slide 192 projects causes the beam 196 to move. When the beam 196 moves, the other slide 192 moves in a corresponding fashion, causing the other dead bolt 174 to also extend or retract. The beam 196 may be maintained in the proper vertical and horizontal planes by a slot 194 and a finger 195.
The glass pane 76 may be made of any type of glass, including safety glass, and may further include decorative patterns on or in the glass. Other glass that may be utilized may include stained glass or glass with decorative metallic caming. If a screen is included, the screen may be made of any suitable material known to those in the art, including metal, plastic, fiberglass or a combination of metal and plastic wire. The glass, screen, or glass and screen combination can be formed in a number of ways.
Installation of the Door System
As illustrated in
Once the orientation is determined, the user may be required to shim the doorframe 56. Shimming the doorframe 56 may insure that the door panel 66 will be properly fitted to the doorframe 56 after installation. As illustrated in
Shims may be preferably one long piece, but may also be smaller sections, such as 8″ or 12″ sections. The shim may be secured to the doorframe 56 by nails or screws and should not extend beyond the doorframe 56 in an exterior direction. Once the doorframe 56 has been shimmed to the required width, the installation of the door panel 66 may proceed.
As illustrated in
As illustrated in
After the glass pane 76 is removed from the door panel 66, the bottom expander 72 may be secured to the bottom side 92 of the door panel 66. The bottom spacer 120 may then be installed to the bottom expander 72 generally near to the hinge side of the bottom expander 72.
As illustrated, the screw receiving holes 180 in the bottom expander 72 may be substantially oval shaped. As will be further discussed in a later step, the oval holes 180 allow the bottom expander 72 to be moved some amount up or down relative to the door panel 66. Movement of the bottom expander 72 may allow the user to custom fit the overall height of the door panel 66 combined with the bottom expander 72 to closely fit the height of the doorframe 56. In other words, the bottom expander 72 may help to cover any gap, or a desired amount of gap, present between the bottom side 92 of the door panel 66 and the bottom 60 of the frame 56. As illustrated in
While the door panel 66 is still in the closed position, pilot holes may be drilled into the doorframe 56 through factory drilled holes in the exterior facing portion of the hinge z-bar 96. Screws may then be inserted through the outside portion of the hinge z-bar 96 to secure the door panel 66 to the doorframe 56. As illustrated in
In the next step of the door system 50 installation, the glass pane 76 (or screen) may be installed into the door panel 66. The present embodiment will be described in terms of installing a glass pane 76, but the installation of any type of glass and/or screen combination may be substantially the same. As shown in
As illustrated in
The next step for installing the door system 50 may include positioning and securing the top mounting frame 68. As illustrated in
The top mounting frame 68 may be then positioned above the door panel 66 and in contact with the top side 58 of the doorframe 56. The door panel 66 may then be closed and the top mounting frame 68 may be lowered until the two factory-installed spacers 110 rest on a top edge of the top side 90 of the door panel 66. The factory installed spacers 110 may insure the correct spacing between the door panel 66 and the top mounting frame 68. Pre-drilled holes in the top mounting frame 68 may then be utilized to secure the top mounting frame 68 to the doorframe 56. The factory installed spacers 110 may be then removed.
As illustrated in
Viewing the lock assembly 80 in the right hinge format, the key cylinder 160, first handle 162, second handle 170, interior and exterior escutcheons 164 and 168, and spindle 166 may be assembled as illustrated. Other components, such as the illustrated washers, retaining clips, etc. may be utilized as illustrated to secure the pieces of the lock assembly together, but will not be separately described. While the lockbody 158 has novel features, the screws, washers, handles, etc. are well-known. The thumb latch 181 of the key cylinder 160 should be oriented to extend towards the interior of the house 54. The interior escutcheon 164 and the exterior escutcheon 168 may fit over the lockbody 158 and the cutouts 94 and may be secured by placing a screw other securing means from an interior side of the house 54 so as to secure the two escutcheons 164 and 168 together. In the present embodiment, activation of the thumb latch 181 engages both of the dead bolts 174.
The handles 162 and 170 and spindle 166 may be secured and tightened utilizing a hex key, but any other type of screw member or tightening member may be utilized. As illustrated best in
As illustrated in
The top and bottom jamb bracket bases 128, 130 may be aligned on an interior side of the house 54. The jamb bracket bases 128, 130 may include breakaway alignment tabs 146. The alignment tabs 146 may include arrows or other indicators that can be aligned with one or more notches 186 factory installed in the storm door, door panel, or hinge z-bar 96 to insure the proper horizontal and vertical placement of the door closer assemblies 82, 84. The notches 186 in the hinge z-bar 96 may be any kind of notch, hole, marking, or removable indicator, such as a sticker.
The same jamb bracket bases 128, 130 may be utilized whether the door panel 66 is mounted in a right hinge or a left hinge format. The “up” orientation indicator and the alignment tab 146 may be printed on both sides of the jamb bracket bases 128, 130 so as to indicate the correct alignment. Once the jamb bracket bases 128, 130 are correctly positioned, the screw insertion points may be utilized to drill pilot holes to the doorframe 56 or interior wall where the jamb bracket bases 128, 130 will be secured. Once screws are inserted to fix the jamb bracket bases 128, 130 in place, the alignment tabs 146 may be removed. The jamb brackets 132, 134 may then be slid over the jamb bracket bases 128, 130 and secured into position. In the present embodiment the jamb brackets 132, 134 may be already pivotally connected to the door closers 124, 126. The door brackets 136, 138 may then be operatively secured to the door closers 124, 126 and to the door panel 66 with screws. In alternative embodiments, the door brackets 136, 138 may be installed to the door panel 66 at the factory. As illustrated, the door brackets 136, 138 have a number of different shaped screw retention points for securing the door closers 124, 126 to the door panel 66. The symmetric design of the top and bottom door closer assemblies 82, 84 and the ability to vertically and horizontally locate the proper position to place the same without additional measuring steps may contribute to the quick installation of the door system 50. Moreover, the predetermined installation length of the door closer 124, 126 allows the same to be connected to the door panel 66 at the proper length to insure the proper tension. The clips 135 may then be removed from the shafts of the door closers 124, 126.
In the next step of installing the door system 50, the position of the bottom expander 72 relative to the door panel 66 may be adjusted. As illustrated in
If any remaining glass elements need to be installed, they may be installed as the last step.
It will be apparent from the foregoing description that is provided a simplified storm door 52 kit and a method for installing the same whereby a single kit may be utilized by a home owner with minimum skill to provide a door which may be hingedly mounted in a left or right hinge format and installed with a reduced amount of time and effort.
With regard to the foregoing description, it is to be understood that changes may be made in the details, without departing from the scope of the present invention. It is intended that the specification and depicted aspects be considered exemplary only, with a true scope and spirit of the invention being indicated by the broad meaning of the following claims.
This application claims the benefit of U.S. provisional application 60/642,847, filed Jan. 11, 2005, which is hereby incorporated by reference in its entirety.
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| Number | Date | Country | |
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| Number | Date | Country | |
|---|---|---|---|
| 60642847 | Jan 2005 | US |
