Patent Application
20240183214
Pre-hung door assemblies generally include a door frame with a door hung therein. The pre-hung door assemblies allow the door to be secured within a rough opening of a wall of a structure and are often more efficient than separately framing and hanging a door within the wall of the structure. Pre-hung door assemblies are typically available in a wide range of sizes and come in a variety of materials, including wood or wood composite, metal, fiberglass, etc. Some known frames for pre-hung door assemblies have jambs with outward extending flanges so that the pre-hung door assembly can be inserted into the rough opening and screws can be used to secure the flanges to the wall (e.g., the flanges being parallel to the wall).
This installation process is generally known to work well for wall constructions that have a planar surface (e.g., wood or steel framed walls with sheathing, concrete, concrete masonry units, etc.) for receiving the jamb flanges. However, some structures may have a wall that is not formed with a planar surface to attach the jamb flange to. For example, modular shipping containers are known to have corrugated wall panels that are not planar surfaces. As such, in some known examples, tubular steel (e.g. Hollow Structural Sections (HSS) 4×2 inches) is known to be used for fabricating a door frame on site. In such circumstances, the tubular steel may be used to construct the frame, and a door may subsequently be hung from the constructed door frame or the flanged frame as described above can be affixed to the tubular steel. Using HSS tube-steel, in particular with on-site installation, is cost and time prohibitive as well as being heavy. Accordingly, improvements are desired.
The present disclosure relates generally to door frames for corrugated walls. In one possible configuration, and by non-limiting example, a pre-hung door assembly is disclosed and having a door frame with a frame member and a track member. The track member forms a planar exterior surface of the door frame so as to facilitate installation within a corrugated wall.
In an aspect, the technology relates to a door frame for a pre-hung door including: a header spanning between a pair of side jambs, wherein each of the pair of side jambs include: a frame member including: a first frame face and an opposing second frame face; a rabbet defined proximate the first frame face such that the first frame face has a first frame width, the rabbet configured to at least partially receive the pre-hung door; a soffit defined proximate the second frame face such that the second frame face has a second frame width, the second frame width being greater than the first frame width; and a first return extending from the first frame face opposite the rabbet and a second return extending from the second frame face opposite the soffit, the first return and the second return defining a throat opening allowing access into an interior cavity of the frame member; and a track member coupled to the frame member enclosing the interior cavity of the frame member, the track member including: a base and two legs extending from each end of the base, the two legs covering at least a portion of the respective first or second frame faces, wherein the base is a substantially planar surface for installing the door frame to a corresponding rough opening on a corrugated wall of a building structure.
In an example, the header includes the frame member and the track member. In another example, a sill is disposed opposite of the header between the pair of side jambs. In yet another example, one side jamb of the pair of side jambs includes at least one hinge cutout disposed at least partially within the rabbet. In still another example, another side jamb of the pair of side jambs includes a strike cutout disposed at least partially within the rabbet. In an example, the track member is welded to the frame member.
In another example, the interior cavity is at least partially sealed. In yet another example, the first frame face has a width that is less than a width of the second frame face. In still another example, a depth of the frame member between the first and second frame faces is 3¾ inches. In an example, the frame member and the track member are 16 Gauge steel.
In another aspect the technology relates to a pre-hung door assembly including: a steel door frame including a header, a first side jamb, and a second side jamb, wherein each of the header and the first and second side jambs include: a frame member including: a first frame face and an opposing second frame face; an interior wall extending between the first and second frames faces, the interior wall including a rabbet and a soffit; and a first return extending from the first frame face and a second return extending from the second frame face, the first and second returns opposite the interior wall, the first return and the second return defining a throat opening allowing access into an interior cavity of the frame member; a track member coupled to the frame member enclosing the interior cavity of the frame member, the track member including: a base and two legs extending from each end of the base, the base covering the throat of the frame member, wherein an exterior surface of the base is substantially planar for installing the door frame to a corresponding rough opening on a corrugated wall of a building structure; and a metal door mounted in the rabbet of the frame member.
In an example, the first frame face has a width that is less than a width of the second frame face. In another example, the two legs of the track member are welded to the respective first or second frame faces of the frame member. In yet another example, a sill extends between the first and second side jambs. In still another example, the second side jamb includes a strike box. In an example, the interior cavity is at least partially sealed.
In another example, a depth of the frame member between the first and second frame faces is 3¾ inches. In yet another example, the frame member and the track member are 16 Gauge steel.
In another aspect, the technology relates to a method of installing a pre-hung door assembly on a modular building having a corrugated wall, the method including: providing the pre-hung door assembly that includes a steel door frame with a frame member and a track member, the frame member having a first frame face and an opposing second frame face, an interior wall extending between the first and second frames faces, the interior wall including a rabbet and a soffit, and a first return extending from the first frame face and a second return extending from the second frame face, the first and second returns opposite the interior wall, the first return and the second return defining a throat opening allowing access into an interior cavity of the frame member, the track member is coupled to the frame member enclosing the interior cavity of the frame member, the track member including a base and two legs extending from each end of the base, the base covering the throat opening of the frame member, the pre-hung door assembly also includes a metal door mounted in the rabbet of the frame member; cutting a rough opening on the corrugated wall of the modular building; at least partially inserting the steel door frame within the rough opening, wherein an exterior surface of the base of the track member is substantially planar for receiving corrugations of the corrugated wall; and welding the corrugated wall to the exterior surface of the base of the track member.
In an example, the interior cavity of the steel door frame is at least partially sealed.
A variety of additional aspects will be set forth in the description that follows. The aspects can relate to individual features and to combinations of features. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the broad inventive concepts upon which the embodiments disclosed herein are based.
The following drawings are illustrative of particular examples of the present disclosure and therefore do not limit the scope of the present disclosure. The drawings are not to scale and are intended for use in conjunction with the explanations in the following detailed description. Examples of the present disclosure will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
Various examples will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various examples does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.
A door frame for a pre-hung door assembly configured for use with corrugated walls, such as walls associated with modular buildings and shipping containers, is described herein. A known process for installing a door to a corrugated wall includes using tube-steel (e.g., HSS shapes) to fabricate a door frame onsite. Once the tube-steel door frame is formed, the door can be added. This process, however, is time consuming and requires a lot of heavy materials. Additionally, known pre-hung door assemblies have door frames with flanges that do not work well with a corrugated wall and result in open gaps between the flange and the wall.
In the examples described herein, the door frame is formed with a two-piece construction having a frame member forming a rabbet and a soffit for hanging the door and a track member that forms an exterior surface that is capable of more easily installing within the corrugated wall. The exterior surface is orthogonal to the corrugated wall when installed so that the door frame can accommodate the corrugations and without gaps being formed in the wall. The door frame can be formed from 16 Gauge steel so that the door assembly is lighter and easier to install. Additionally, the door frame can be assembled in a factory and the door pre-hung so that on-site installation is easier.
As used herein, interior and exterior areas of the door frame 100 are being used to refer to the position of the door within the door frame 100 and not relative to interior and exterior sides of the corrugated wall 118. It should be appreciated that the door frame 100 may have inside areas (e.g., the second side wall 128) and outside areas (e.g., the first side wall 126) that refer to inside and outside area of the corrugated wall 118. In other examples, the corrugated wall 118 may not define inside and outside areas, but rather a first area and a second area both inside the building structure. In this example, the corrugated wall 118 and door 102 form a boundary between the first area and the second area.
The side jamb 104, 106 is formed with two-piece construction and includes a frame member 130 and a track member 132 that are coupled together to form the side jamb 104, 106 for the door 102. The frame member 130 is formed with a plurality of wall portions that are orthogonal to each other. In the example, the frame member 130 includes a first frame face 134 and an opposite second frame face 136. The first frame face 134 is parallel to the second frame face 136. The first frame face 134 forms at least a portion of the first side wall 126 and the second frame face 136 forms at least a portion of the second side wall 128. The interior wall 120 is formed by the frame member 130 and extends between the first and second frame faces 134, 136. The interior wall 120 includes a rabbet 138 defined proximate the first frame face 134 and a soffit 140 defined proximate the second frame face 136.
The rabbet 138 defines a recess within the interior wall 120 and so as to at least partially receive the door 102. The soffit 140 is a projection of the interior wall 120. A stop portion 142 extends between the rabbet 138 and the soffit 140 and is configured to restrict the door 102 from swinging all the way through the door frame 100. The stop portion 142 is disposed between and is substantially parallel to the first and second frame faces 134, 136. The rabbet 138 and the soffit 140 portions are substantially parallel to each other while being offset relative to one another via the stop portion 142. The first frame face 134 has a first frame width 144 and the second frame face 136 has a second frame width 146, the first frame width 144 is less than the second frame width 146. As such, the second frame width 146 is greater than the first frame width 144.
A first return 148 extends orthogonally from the first frame face 134 and opposite the rabbet 138. A second return 150 extends orthogonally from the second frame face 136 and opposite the soffit 140. The first return 148 and the second return 150 are substantially parallel to the interior wall 120. The first return 148 and the second return 150 define a throat opening 152 that allows access into an interior cavity 154 of the frame member 130 from the side. Because of the throat opening 152, the frame member 130 alone does not provide an exterior surface for the corrugated wall 118 to be secured to the frame member 130 at the location of the exterior wall 122. As such, the track member 132 is coupled to the frame member 130 so as to enclose the interior cavity 154 and cover the throat opening 152.
The track member 132 is a substantially U-shaped channel having a base 156 with a first leg 158 and a second leg 160 extending from each respective end of the base 156. In the example, the first and second legs 158, 160 extend in the same direction and are substantially parallel to each other. The first and second legs 158, 160 are orthogonal to the base 156. The outside surface of the track member 132 provides the exterior surface 124 for the door frame 100 that allows the corrugated wall 118 to be more easily secured to the side jamb 104, 106 as described herein.
In the example, the first leg 158 covers at least a portion of the first frame face 134 and may form a portion of the first side wall 126. The first return 148 is positioned against the inside of the base 156 of the track member 132. The second leg 160 covers at least a portion of the second frame face 136 and may form a portion of the second side wall 128. The second return 150 is positioned against the inside of the base 156 of the track member 132. The base 156 of the track member 132, along with the first and second returns 148, 150, form the exterior wall 122 of the side jamb 104, 106 and the outside of the base 156 forms a substantially planar exterior surface 124 for securing the side jamb 104, 106 to the corrugated wall 118. Additionally, the track member 132 covering the throat opening 152 provides weather resistance to the side jamb 104, 106 and creates a seal for the door frame 100. As such, the interior cavity 154 is configured to be at least partially sealed. In some examples, insulation material(s) may be disposed within the interior cavity 154.
While
In the example, the track member 132 may be welded to the frame member 130 so as to couple the two members together. In an example, the track member 132 may be spot welded (e.g., not a continuous weld) to the frame member 130 at predetermined spacing intervals. As shown in
Both the frame member 130 and the track member 132 may be formed from steel. In an aspect, the steel may be galvanized to protect the door frame from environmental elements that cause corrosion and rust. In other aspects, the frame member 130 or track member 132 may be formed from aluminum, stainless steel, or other appropriate building materials. In examples, the frame member 130 and the track member 132 may be between 10 and 22 Gauge steel. In an aspect, the frame member 130 and the track member 132 may be at least 16 Gauge steel. In the example, both the frame member 130 and the track member 132 both are formed from 16 Gauge steel. In other examples, the frame member 130 and the track member 132 may be formed from different gauged steel as required or desired. For example, the track member 132 may be formed from a lower gauge steel than the frame member 130. By using 16 Gauge steel the door frame 100 is much lighter than if the door frame is formed out of HSS tube-steel members. For example, the door frame 100 may weigh around 52-pounds and a single person can move the door frame 100 around and even with the door therein.
In the example, the cross-sectional profile of the frame member 130 and the track member 132 may be formed via a bending and a cutting and/or punching process. In other examples, the frame member 130 and/or the track member 132 may be formed from materials that allow for other types of manufacturing processes, such as, but not limited to, extrusion processes, additive manufacturing processes, etc.
A depth 164 of the side jamb 104, 106 is defined between the first frame face 134 and the second frame face 136 can be sized for the corrugated wall 118 and door 102 used. In one example, the depth 164 may be 4¾ inches. In another example, the depth 164 may be 3¾ inches. A depth 164 of 3¾ inches may be utilized in the case of typical depth of corrugations in the corrugated wall to which the door frame 100 is installed, and utilized in a corrugated wall of a shipping container. In such cases, the reduced depth may be advantageous in that it reduces the extent to which the door frame 100 extends into an interior of a shipping container. This reduces the effective interior space within that container and/or allows a thinner wall finishing to be applied on an interior wall of the shipping container over the corrugated surface, when such finishing is desirable (e.g., in retrofit applications converting shipping containers into occupiable building components).
Referring back to
The door 102 may be a metal door and in some examples be formed out of galvanized steel. In an aspect, the door 102 may be a 20 Gauge steel door. In examples, the door 102 may be insulated (e.g., polystyrene) as required or desired. As illustrated, a single door is hung within the door frame 100. In other examples, double doors may be hung within the door frame 100. The door 102 is pre-hung within the door frame 100 so the door assembly 182 can be more efficiently installed. The pre-hung door assembly 182 is easily shipped and assembly can be controlled in the factory. In other examples, the door 102 and door frame 100 may be shipped as a disassembled kit and assembled on-site as required or desired.
In the example, the door 102 is positioned towards the first frame face 134 and the door 102 is pulled outward from the first frame face 134 to open. The first frame face 134 may correspond to an outside area of the corrugated wall 118.
In general, the corrugated wall 118 is an uneven wall (e.g., has both x and y axis components), and thus, providing a flange planar in the x-axis direction as previously known with pre-hung door assemblies results in gaps formed between the flange and the wall. In the door frame 100 described herein, the header 108 forms the exterior surface 124 as a planar surface in the x-y plane, and thus, the exterior surface 124 facilitates installing the door frame 100 to the corrugated wall 118 without gaps forming. Similarly, when looking at the exterior surface 124 of the first and second side jambs 104, 106 (shown in
As described above, a depth of 3¾ inches may be utilized so as to reduce the extent to which the door frame 100 extends into an interior of the shipping container. This reduces the effective interior space within the container and/or allows a thinner wall finishing to be applied on an interior space within that container and/or allows a thinner wall finishing to be applied on an interior wall of the shipping container over the corrugated surface, when such a finishing is desirable.
The method may begin with providing the pre-hung door assembly (operation 202). In the example, the pre-hung door assembly may be assembled in a factory and shipped to the site of the modular building. In other examples, the pre-hung door assembly may be shipped as a kit and assembled on-site as required or desired. The pre-hung door assembly includes a steel door frame with a frame member and a track member. The frame member has a first frame face, and opposing second frame face, an interior wall extending between the first and second frames faces, the interior wall including a rabbet and a soffit, a first return extending from the first frame face, and a second return extending from the second frame face. The first and second returns are disposed opposite the interior wall and define a throat opening allowing access into an interior cavity of the frame member. The track member is coupled to the frame member enclosing the interior cavity of the frame member. The track member includes a base and two legs extending from each end of the base with the base covering the throat opening of the frame member. The pre-hung door assembly also includes a metal door mounted at least partially within the rabbet of the frame member.
A rough opening is cut on the corrugated wall of the modular building (operation 204). The tools for cutting the corrugated wall are known to one of ordinary skill in the art and may include, for example, an angle grinder, reciprocating saw, plasma cutter, or the like. The rough opening in the corrugated wall is sized to receive the exterior surface of the door frame and the door frame size is based on the door being hung therein (e.g., a single door, a double door, and the various door sizes thereof).
Once the rough opening is cut, the steel door frame is at least partially inserted within the rough opening of the corrugated wall (operation 206). An exterior surface of the base of the track member is substantially planar for receiving the cut edge corrugations of the corrugated wall. When the door frame is positioned within the rough opening, the exterior surface of the track member is substantially orthogonal to the corrugated wall. The door frame is at least partially sealed, thereby providing a weather seal at the corrugated wall. Additionally, the door frame may include a sill that provides a threshold for the pre-hung door assembly.
The corrugated wall may then be welded to the exterior surface of the base of the track member (operation 208) so as to secure the door frame within the rough opening. The exterior surface of the door frame provides a square surface that accommodates the uneven corrugations. Once the door frame is secured to the corrugated wall, sheathing and/or molding may be installed as required or desired. By utilizing the door frame construction described herein, there is no longer a need to fabricate a tubular steel frame on-site for the rough opening and then also add a door to the tubular steel frame. Accordingly, installation time and costs are reduced. For example, by using the pre-hung door assembly, at least an hour or two of welding and frame fabrication is eliminated, in addition to material allocation time.
References in the specification to “one example,” “an example,” “an illustrative example,” etc., indicate that the example described may include a particular feature, structure, or characteristic, but every example may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same example. Further, when a particular feature, structure, or characteristic is described in connection with an example, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other examples whether or not explicitly described. Additionally, it should be appreciated that items included in a list in the form of “at least one A, B, and C” can mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C). Similarly, items listed in the form of “at least one of A, B, or C” can mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C). Moreover, one having skill in the art will understand the degree to which terms such as “about,” “approximately,” or “substantially” convey in light of the measurements techniques utilized herein. To the extent such terms may not be clearly defined or understood by one having skill in the art, the term “about” shall mean plus or minus ten percent.
From the forgoing detailed description, it will be evident that modifications and variations can be made in the aspects of the disclosure without departing from the spirit or scope of the aspects. While the best modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims.
This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/430,431, filed Dec. 6, 2022, the disclosure incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63430431 | Dec 2022 | US |
