The invention is directed to pocket doors used in residential and commercial properties and, in particular, to a pocket door frame assembly that maintains rigidity to prevent pocket door failures.
A “pocket door” is commonly used in homes and offices to provide a unique space saving feature. Pocket doors can be hidden in a wall by use of a recessed compartment placed in a wall cavity. In modern home and building construction, partition walls are normally constructed from wood studwork covered with a wall skin, such as drywall, sheetrock, plasterboard or the like. The pocket door design requires a builder to leave space in the studwork for a doorway and also for an internal cavity into which a sliding door may be concealed. For this reason, part of the pocket door frame must include the necessary studwork for support of the wall skin. The door frame supports the outer skin of the wall providing wall strength, and providing a frame for the sliding door to travel within. The result is very good space saving characteristics and a contemporary design, as there is no encroachment of a conventional hinged door into the adjoining room. Modern designers realize this and, as a result, pocket doors have made a resurgence in recent years.
However, conventional pocket door frames are known to sag or outright fail over time due to inadequate construction design. The conventional frame relies upon a substandard support for the wall skin which will eventually allow warpage as the frame ages. The conventional frame employs a minimal amount of structural rigidity by relying upon adjacent wall panels for support. Further, conventional framing can be installed improperly, or damaged during installation, due to the required reliance on adjacent wall boards to provide reinforcement. Additionally, the framing can warp over time due to acclimation such as wood and wall board strength variation due to moisture affecting rigidity. Aluminum U-shaped channels were added in an attempt to correct the problem, but the channels can easily be damaged and relying upon adjacent wall boards for strength result in the same failures. Conventional pocket door frames use nails as fasteners which fail to permanently bond members together.
In light of the above, conventional pocket door frames eventually fail resulting in the pocket door rubbing on the frame and making it difficult to open or close. Once the framing for a pocket door fails the frame needs to be replaced, which is complicated task as part of the wall has to be opened. Due to the failure of conventional pocket door, the reputation of pocket doors has soured.
What is needed in the industry is a pocket door frame having a construction technique to address and eliminate pocket door frame warping frame.
Disclosed is an improved pocket door frame for a sliding door that resists or eliminates frame warping with minimal weight change from conventional pocket door frames. The pocket door frame has a reinforced header and two partial plywood panels constructed and arranged to provide dimensional stability by preventing twisting of the frame. The frame has a header support with an overhead track attached by T-nuts for ease of installation and replacement. A pair of vertical spreaders carry the header support and form a pocket recess entrance. A vertical stud member is attached to an end of the header support with a plurality of horizontal slats coupled to the vertical spreaders. The horizontal slats are evenly spaced and attached in square alignment with plywood panels extending from a base to the header support and fastened to the horizontal slats and vertical stud member. A first and second header spacer positioned perpendicular to a lower surface of the header support extends outwardly from the pocket recess. A first and second header frame member is positioned perpendicular to the first and second header spacer and extends outwardly from the pocket recess.
An objective of the invention is to provide an improved pocket door frame assembly that prevents warpage by providing reinforcement at critical failure locations.
Another objective of the invention is to provide an improved pocket door frame assembly using primed finger joint pine and plywood leading to long term dimensional stability.
Still another objective of the invention is to employ partial plywood panels that are stapled and glued to the horizontal slats and vertical spreaders for increased stability during shipping and installation.
Yet still another objective of the invention is to provide a header with T-nuts, allowing ease of track installation and replacement.
Another objective of the invention is to use a centering block attached to the header during installation, ensuring no side to side movement of the track.
Still another objective of the invention is to eliminate the need for a metal typically used for stability in a conventional frame.
Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification, include exemplary embodiments of the present invention, and illustrate various objects and features thereof.
A detailed embodiment of the instant invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the invention. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
Referring now to the figures, illustrated is a pocket door frame 10 for a sliding door hung from a header support 12 having a length (L1) and a width (W1). A track 14 is attached to the header support 12 by use of a plurality of T-bolts 16 wherein a fastener 18 is removably attached to each T-bolt 16, allowing ease of track 14 maintenance or replacement. During installation of the pocket door frame, a centering block 20 is attached to a lower surface of the header support 12 to ensure no side to side movement of the track 14 is possible.
A first vertical spreader 22 and a second vertical spreader 24 extend from a base 25 to the header support 12 in a spaced apart position. Each vertical spreader 22, 24 is made from laminated ¾ inch primed finger joint pine and is stapled and glued to the header support 12 forming a spaced apart opening of about 2¼ inches (W1). The first vertical spreader 22 forms an “L” shape by use of a laminated base block 26 forming a width (W2) of about 1½ inches with the base block 26 glued and stapled to the vertical spreader 22. Similarly, the second vertical spreader 24 forms an “L” shape by use of a laminated second base block 26′ forming a width (W3) of about 1½ inches with the second base block 26′ glued and stapled to the second vertical spreader 24. The first and second vertical spreaders 22, 24 form a pocket recess entryway constructed and arranged to receive a sliding door, not shown.
A vertical stud member 30 is attached to an end 32 of the header support 12, and a plurality of horizontal slats positioned on each side of the vertical spreaders 22, 24 and vertical stud member 30, with all connections using pneumatically driven staples and wood glue at all joined points. The horizontal slats 34 are made of ½ inch primed finger joint pine stapled and glued using an installation jig, not shown, to ensure even spacing and square alignment. The horizontal slats 34 are evenly spaced apart and extend from the base block 26. In a preferred embodiment, first lower slat 40, 40′ is 5¼ inches tall; second slat 42, 42′ is 3½ inches tall; third slat 44, 44′ is 3½ inches tall; fourth slat 46, 46′ is 3½ inches tall; fifth slat 48,48′ is 3½ inches tall; sixth slat 50, 50′ is 3½ inches tall; and top slat 52, 52′ is 1½ inches tall and is coupled to the bottom surface of the header support 12, forming a first side. Similarly, a second side is formed by a first lower slat 40′ that is 5¼ inches tall; a second slat 42′ that is 3½ inches tall; a third slat 44′ that is 3½ inches tall; a fourth slat 46′ that is 3½ inches tall; a fifth slat 48′ that is 3½ inches tall; a sixth slat 50′ that is 3½ inches tall; and a top slat 52′ that is 1½ inches tall and is coupled to the bottom surface of the header support 12, forming a second side of the pocket recess. The dimensions provided are for a typical 3 foot by 8 foot doorway.
Along the first side is placed a first plywood panel 60 extending from the base 25 to the header support 12, the plywood being ⅛ inch thick and about 7¾ inches wide and fastened to each of the horizontal slats 34 positioned on the first side. The second side has a second plywood panel 62 extending from the base 25 to the header support 12, the plywood being ⅛ inch thick and about 16 inches wide and fastened to each of the horizontal slats 34 positioned on the second side.
Vertical spreaders 22, 24 are positioned about halfway along the length of the header support 12. A first header spacer 70 is positioned perpendicular to a lower surface 72 of the header support 12 and extends outwardly from the pocket recess. A first header frame member 74 is positioned perpendicular to the first header spacer 70 and extends outwardly from the pocket recess. The first header spacer 70 is stapled and glued to the header support 12. The first header frame member 74 is stapled and glued to the first header spacer 70. A second header spacer 70′ is positioned perpendicular to a lower surface 72 of the header support 12 and extends outwardly from the pocket recess. A second header frame member 74′ is positioned perpendicular to the second header spacer 70′ and extends outwardly from the pocket recess. The second header spacer 70′ is stapled and glued to the header support 12. The second header frame member 74′ is stapled and glued to the second header spacer 70′.
The pocket door frame 10 is constructed and arranged to provide dimensional stability and prevent warping or twisting of the frame when subject to years of environmental pressures such as fluctuating heat and humidity levels.
The term “about” means, in general, the stated value plus or minus 5%. The use of the word “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more” or “at least one.” The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a method or device that “comprises,” “has,” “includes” or “contains” one or more steps or elements, possesses those one or more steps or elements, but is not limited to possessing only those one or more elements.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims.
In accordance with 37 C.F.R. § 1.76, a claim of priority is included in an Application Data Sheet filed concurrently herewith. Accordingly, the present invention claims priority to U.S. Provisional Patent Application No. 63/382,911 entitled “IMPROVED POCKET DOOR FRAME ASSEMBLY”, filed Nov. 9, 2022. The contents of which the above referenced application is incorporated herein by reference.
Number | Date | Country | |
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63382911 | Nov 2022 | US |