Patent Application
20220003035
This disclosure relates to a quick-install door system, such as a storm door, and components thereof.
Briefly, the present disclosure provides A ready-to-install door system comprising, prior to installation a door, which is rotatably attached on a hinge-side edge to a hinge-side z-bar, which is attached at a top end to a drip cap, which is attached to a top end of a latch-side z-bar; where the system comprises door closer hardware attached to the door and either the drip cap or the hinge-side z-bar.
In one aspect, the present disclosure provide a ready-to-install door system comprising, prior to installation: a) a door, which is rotatably attached on a hinge-side edge to b) a hinge-side z-bar, which is permanently attached at a top end to c) a drip cap, which is permanently attached to a top end of d) a latch-side z-bar; where the system comprises door closer hardware, the door closer hardware comprising a closer arm rotatably attached to a slider which is slideably attached to the drip cap. In some embodiments, the door comprises door closer hardware contained within the thickness of the door.
In another aspect, the present disclosure provides a ready-to-install door system comprising, prior to installation: a) a door, which is rotatably attached on a hinge-side edge to b) a hinge-side z-bar, which is permanently attached at a top end to c) a drip cap, which is permanently attached to a top end of d) a latch-side z-bar; wherein the latch-side z-bar or, more typically, the hinge-side z-bar comprises an installation notch near its top end.
In another aspect, the present disclosure provides a ready-to-install door system comprising, prior to installation: a) a door, which is rotatably attached on a hinge-side edge to b) a hinge-side z-bar, which is permanently attached at a top end to c) a drip cap, which is permanently attached to a top end of d) a latch-side z-bar; where at least one of the z-bars comprises at least one screw holder assembly comprising: e) a screw holder mounting hole in the z-bar; f) a screw holder mounted in the screw holder mounting hole; and g) a screw driven into the screw holder.
In another aspect, the present disclosure provides a screw holder adapted to hold a screw in a stable position relative to a screw holder mounting hole in a first substrate, prior to driving the screw to attach the first substrate to a second substrate, comprising: a) a screw holder body having a screw-point end, pointing in a screw-point direction, and a screw-head end, pointing in a screw-head direction, having a hollow interior open at the screw-head end for receiving a screw into the hollow interior, where the screw holder body has an outer perimeter adapted to fit into the screw holder mounting hole in the first substrate; b) a collar portion at the screw-point end of the screw holder body adapted to prevent the screw holder from passing entirely through the screw holder mounting hole in the screw-head direction; c) one or more locking extensions extending from the screw holder body, which are compressible against or into the screw holder body to allow the screw holder to be inserted into the screw holder mounting hole in the screw-head direction and which rebound after insertion to prevent the screw holder from passing out of the screw holder mounting hole in the screw-point direction.
In another aspect, the present disclosure provides methods of installing a ready-to-install door system comprising the steps of: a) providing a ready-to-install door system according to the present disclosure; b) driving an installation screw into a frame of a door opening at a pre-determined distance from the top of the door opening; c) positioning the ready-to-install door system so that it hangs from the installation screw by the installation notch; and d) further attaching the ready-to-install door system to the frame of the door opening, typically by fully driving screws mounted in screw holders.
In yet another aspect, the present disclosure provides a ready-to-install door system comprising, prior to installation: a door, which is rotatably attached on a hinge-side edge to a hinge-side z-bar, which is attached at a top end to a drip cap, which is attached to a top end of a latch-side z-bar; where at least one of the z-bars includes at least one preloaded screw and a mounting hole.
In even yet another aspect, the present disclosure provides a screw holder adapted to hold a screw in a stable position relative to a mounting hole in a first substrate, prior to driving the screw to attach the first substrate to a second substrate, comprising a) a screw holder body having a screw-point end, pointing in a screw-point direction, and a screw-head end, pointing in a screw-head direction, having a hollow interior open at the screw-head end for receiving a screw into the hollow interior, where the screw holder body has an outer perimeter adapted to fit into the mounting hole in the first substrate; b) a collar portion at the screw-point end of the screw holder body adapted to prevent the screw holder from passing entirely through the mounting hole in the screw-head direction; and c) one or more locking extensions extending from the screw holder body, which are compressible against or into the screw holder body to allow the screw holder to be inserted into the mounting hole in the screw-head direction and which rebound after insertion to prevent the screw holder from passing out of the mounting hole in the screw-point direction.
In a further aspect, the present disclosure provides a method of installing a ready-to-install door system comprising the steps of: a) providing a ready-to-install door system including: a door, which is rotatably attached on a hinge-side edge to a hinge-side z-bar, which is attached at a top end to a drip cap, which is attached to a top end of a latch-side z-bar; where at least one of the z-bars comprises at least one screw and a mounting hole, b) positioning the ready-to-install door system within or adjacent to a frame of the door opening; and c) attaching the ready-to-install door system to the frame of the door opening with the at least one preloaded screw.
Additional embodiments of the door systems, screw holders, and methods of the present disclosure are described below under “Selected Embodiments.”
The preceding summary of the present disclosure is not intended to describe each embodiment of the present invention. The details of one or more embodiments of the invention are also set forth in the description below. Other features, objects, and advantages of the invention will be apparent from the description and from the claims.
In this application:
All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified.
As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.
As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open ended sense, and generally mean “including, but not limited to.” It will be understood that the terms “consisting of” and “consisting essentially of” are subsumed in the term “comprising,” and the like.
It is an advantage of the present disclosure to provide a door system which may be installed rapidly, typically in less than 10 minutes.
The present disclosure provides a quick-install door system and unique components thereof.
The disclosed door system provides installation advantages when compared, for example, to a conventional or traditional storm door installation kit. The installation of the present door system is much quicker and more efficient. Pre assembly of the closer and lockset avoid the time-consuming steps of separate installation processes required by a conventional kit. In addition, the pre-assembled door system allows the installer to easily position and hang the door system from a single installation screw in a framed door opening in a single operation. All the components are properly positioned in a single step. Further, pre-loading the installation z-bar screws in the disclosed screw holders or screw holder assemblies allows the installer to quickly drive the screws without having the potential for the door components to move or shift position when driving individual installation screws and the preloaded screws are all driven from the readily accessible front of the door system. Still further, pre-assembly of the door system ensures the system components remain properly aligned with respect to each other during the installation. Proper alignment of the system components avoids any potential binding or other problems, for example, of the door opening, closing and latching.
With reference to
The disclosed door system is readily installed in, within, or adjacent to a framed door opening using the following steps.
An installation screw 490 is fitted to the door frame (e.g., of a door opening) using a template 480. As illustrated in
The door system is fitted in the door frame by hanging the door system from the installation screw 490 using the installation notch 80 in the upper portion of the hinge z-bar 420. The isometric view of
According to some embodiments, the screw holder assembly 70 can include a preloaded screw, which can be preloaded into screw holders. A preloaded screw, as used herein, can denote a screw that was pre-installed into a screw holder 10 prior to sale or prior to leaving a place of manufacture, such as a factory.
Once the door system is hung from the installation screw, the preloaded hinge and latch z-bar screws are driven into the door frame. It is an advantage of an embodiment of the present system that all of these screws are front facing and preloaded into the screw holders, for easier installation. In addition, installation screws are driven into the door frame to secure the drip cap. The drip cap includes holes for positioning these installation screws.
Once the drip cap, hinge and latch z-bar installation screws are secured, the upper and lower z-bar clips 210 are removed from the latch z-bar 100 and door 410 by first removing the screws securing the clips to the latch z-bar. The expanded view of
When the door is opened, the lockset live bolt retainer 310, to keep the live bolt in a retracted position, may also be removed in order to allow the live bolt to move in and out of the lockset in a conventional manner. Without the retainer, the live bolt would extend into a mating hole in the latch z-bar, preventing the door from being able to be opened since the lockset handles have not yet been fitted (and can't be since the door would still be latched in the closed position). With the door opened, additional installation screws are driven into holes located in the drip cap to further secure the drip cap to the door frame.
The bottom expander 460 may be adjusted for the bottom of the door system to properly align with the threshold of the door frame. This adjustment allows for the seal at the bottom the expander to lightly brush against the threshold.
If needed, adjustments may be made to the closer 440 in order to set the door swing positioning and hold-open stop 447. Preferably the hold-open stop 447 has been preinstalled to hold the door open at 90° without any adjustment necessary by the installer. However, if physical obstructions prevent the door from opening to a full 90° or it is desired to hold the door open at an angle slightly greater than 90°, the location of the hold-open stop can be adjusted to hold the door open at some other desired angle. The closer, for example, may be adjusted to allow the door to open 90° and then engaged the hold-open stop.
a-c, and 11a-d depict one embodiment of a screw holder 10 according to the present disclosure. As described herein, the screw holder 10 can be a part of a screw holder assembly 70. Screw holder 10 includes a screw holder body 20 having the appropriate perimeter or circumference to fit a screw holder mounting hole in a first substrate such as z-bar 100. The screw holder has a screw-point end C, pointing in a screw-point direction D, and a screw-head end A, pointing in a screw-head direction B. The screw holder body 20 has a hollow interior open at the screw-head end A for receiving a screw 120 into the hollow interior. Typically, the screw holder body 20 is also open at the screw-point end C; however, in some embodiments screw-point end C is closed until pierced by screw 120 when screw 120 is driven into the second substrate (not shown). Screw holder 10 includes a collar portion 30 at the screw-point end C of the screw holder body 20 adapted to prevent screw holder 10 from passing entirely through the screw holder mounting hole in the screw-head direction B. In some embodiments, screw holder 10 includes one or more locking extensions 40 extending from screw holder body 20, which are compressible against or into screw holder body 20 to allow screw holder 10 to be inserted into the screw holder mounting screw in the screw-head direction B. Locking extensions 40 rebound after insertion to prevent screw holder 10 from passing out of the screw holder mounting screw in the screw-point direction D. In some embodiments, locking extensions 40 splay out flat against the substrate (such as z-bar 100) when screw 120 is fully driven into screw holder 10 (see splayed locking extension 40a in
The screw holder 10 may be made of any suitable material. In some embodiments, the screw holder 10 is a unitary construction comprising a single piece of material. In some embodiments, the screw holder material is a polymeric material. In some embodiments, the screw holder material is a thermoplastic material. In some embodiments, the screw holder material is a moldable material. In some such embodiments, the screw holder is a unitary construction made in a single molding. In some embodiments, where the screw holder 10 provides mechanical isolation between the first and second substrates, the screw holder material is an elastomeric material. In some embodiments, where the screw holder 10 provides electrical isolation between the first and second substrates, the screw holder material is an electrically non-conductive material.
The first substrate may be made of any suitable material. Suitable materials may include metals, plastics, fiber/resin composites, glass, ceramic or stone; and are most typically metals. The second substrate may be made of any suitable material for attachment by a screw, which may include wood, plastic, sheet metal, or the like. The screw may be of any suitable type, which may include wood screws or sheet metal screws.
The z-bar clip may be made of any suitable material. In some embodiments, the z-bar is a unitary construction comprising a single piece of material. In some embodiments, the z-bar material is an extruded material. In some embodiments, the z-bar material is a polymeric material. In some embodiments, the z-bar material is a thermoplastic material. In some embodiments, the z-bar material is a moldable material. In some such embodiments, the z-bar is a unitary construction made in a single molding. In this embodiment the screw holder mounting screws may be added in a secondary step after the z-bar is made.
The live bolt retainer 310 may be made of any suitable material. In some embodiments, the live bolt retainer 310 is a unitary construction comprising a single piece of material. In some embodiments, the live bolt retainer material is a polymeric material. In some embodiments, the live bolt retainer material is a thermoplastic material. In some embodiments, the live bolt retainer material is a moldable material. In some such embodiments, the live bolt retainer 310 is a unitary construction made in a single molding.
Additional embodiments are recited in the Selected Embodiments and Examples below.
The following embodiments, designated by letter and number, are intended to further illustrate the present disclosure but should not be construed to unduly limit this disclosure.
SH1. A screw holder adapted to hold a screw in a stable position relative to a screw holder mounting hole in a first substrate, prior to driving the screw to attach the first substrate to a second substrate, comprising:
a) a screw holder body having a screw-point end, pointing in a screw-point direction, and a screw-head end, pointing in a screw-head direction, having a hollow interior open at the screw-head end for receiving a screw into the hollow interior, wherein the screw holder body has an outer perimeter adapted to fit into the hole in the first substrate;
b) a collar portion at the screw-point end of the screw holder body adapted to prevent the screw holder from passing entirely through the hole in the screw-head direction;
c) one or more locking extensions extending from the screw holder body, which are compressible against or into the screw holder body to allow the screw holder to be inserted into the screw holder mounting hole in the screw-head direction and which rebound after insertion to prevent the screw holder from passing out of the screw holder mounting hole in the screw-point direction.
SH2. The screw holder according to any of the preceding embodiments wherein the hollow interior of the screw holder body is also open at the screw-point end of the screw holder body.
SH3. The screw holder according to any of the preceding embodiments additionally comprising an orienting projection on the side of the collar portion that faces the screw-head end of the screw holder body.
SH4. The screw holder according to any of the preceding embodiments comprising a polymeric material.
SH5. The screw holder according to any of the preceding embodiments comprising a moldable material, where the screw holder is a unitary construction made in a single molding.
SH6. The screw holder according to any of the preceding embodiments which is a unitary construction comprising a single piece of material.
SH7. The screw holder according to any of the preceding embodiments wherein the one or more locking extensions are adapted to splay out flat against a first substrate when the screw holder is mounted in a screw holder mounting hole in the first substrate and a screw is fully driven into the screw holder.
SH8. The screw holder according to any of the preceding embodiments wherein the screw holder body comprises wall segments adapted to fold outward when the screw holder is mounted in a screw holder mounting hole in the first substrate and a screw is fully driven into the screw holder.
SH9. The screw holder according to any of the preceding embodiments additionally comprising break lines comprising furrows and/or perforations running lengthwise from the screw-head end of the screw holder body toward the screw-point end of the screw holder body, the break lines being adapted to break when the screw holder is mounted in a screw holder mounting hole in the first substrate and a screw is fully driven into the screw holder.
SHA1. An assembly comprising a first substrate comprising a screw holder mounting hole, a screw holder according to any of the preceding embodiments mounted in the screw holder mounting hole, and a screw driven into the screw holder at the screw-head end so as to extend not more than 5.0 mm beyond the screw-point end of the screw holder.
SHA2. The assembly according to embodiment SHA1 wherein the screw is driven into the screw holder at the screw-head end so as to extend not more than 1.0 mm beyond the screw-point end of the screw holder.
SHA3. The assembly according to embodiment SHA1 wherein the screw is driven into the screw holder at the screw-head end so as to not extend beyond the screw-point end of the screw holder.
SHA4. The assembly according to any of embodiments SHA1-SHA3 wherein the first substrate comprises a material selected from metals, plastics, fiber/resin composites, glass, ceramic or stone.
SHA5. The assembly according to any of embodiments SHA1-SHA3 wherein the first substrate comprises a material selected from metals.
SHA6. The assembly according to any of embodiments SHA1-SHA5 wherein the screw is a wood screw.
SHA7. The assembly according to any of embodiments SHA1-SHA5 wherein the screw is a sheet metal screw.
SHA8. The assembly according to any of embodiments SHA1-SHA7 wherein the screw holder mounting hole includes a positioning notch and the screw holder additionally comprises an orienting projection on the side of the collar portion that faces the screw-head end of the screw holder body, where the orienting projection is adapted to fit into the positioning notch.
ZC1. A z-bar clip adapted to hold a door in a stable position relative to a latch-side z-bar of a door frame by attachment to the door and to a front surface of the z-bar, comprising:
a) a generally planar door attachment portion comprising a first screw holder mounting hole; connecting to
b) a generally planar first connecting portion; connecting to
c) a second connecting portion; connecting to
d) a generally planar z-bar attachment portion comprising a second screw holder mounting hole;
wherein a) and b) are generally plane-perpendicular to each other;
wherein a) and d) are generally plane-perpendicular to each other;
wherein b) and d) are generally plane-parallel to each other; and
wherein the z-bar clip has a consistent cross-section along a length dimension, excepting first and second screw holder mounting holes.
ZC2. The z-bar clip according to embodiment ZC-1 wherein second connecting portion c) is curved.
ZC3. The z-bar clip according to embodiment ZC-1 or ZC-2 wherein the first hole is a keyhole-shaped hole.
ZC4. The z-bar clip according to any of embodiments ZC-1 to ZC-3 comprising a polymeric material.
ZC5. The z-bar clip according to any of embodiments ZC-1 to ZC-4 comprising a moldable material, where the z-bar clip is a unitary construction made in a single molding.
ZC6. The z-bar clip according to any of embodiments ZC-1 to ZC-5 which is an extruded or unitary construction comprising a single piece of material.
ZCA1. An assembly comprising a door mounted in a door frame comprising a latch-side z-bar, wherein the door is held in a stable position relative to the latch-side z-bar by a z-bar clip according to any of embodiments ZC-1 to ZC-6.
ZCA2. An assembly according to embodiment ZCA1 wherein the door attachment portion of the z-bar clip as attached to the door by a screw passing through the first hole.
ZCA3. An assembly according to embodiment ZCA1 or ZCA2 wherein the z-bar attachment portion of the z-bar clip is attached to the z-bar by a screw passing through the second hole.
BR1. A live bolt retainer adapted to retain in a retracted position a live bolt which emerges from a bolt hole in the edge of a door, comprising:
a) a generally planar bolt retaining portion; and
b) one or more clip portions adapted to engage and hold edges of a bolt hole in the edge of a door.
BR2. The live bolt retainer according to embodiment BR-1 comprising two clip portions.
BR3. The live bolt retainer according to embodiment BR-1 or BR-2 comprising a polymeric material.
BR4. The live bolt retainer according to any of embodiments BR-1 to BR-3 comprising a moldable material, where the live bolt retainer is a unitary construction made in a single molding.
BR5. The live bolt retainer according to any of embodiments BR1 to BR-4 which is a unitary construction comprising a single piece of material.
DS1. A ready-to-install door system comprising, prior to installation:
a) a door, which is rotatably attached on a hinge-side edge to
b) a hinge-side z-bar, which is permanently attached at a top end to
c) a drip cap, which is permanently attached to a top end of
d) a latch-side z-bar.
DS2. The door system according to embodiment DS1 wherein the door comprises latch hardware comprising at least one bolt capable of securing the door in a closed position after installation.
DS3. The door system according to embodiment DS1 wherein the door comprises latch hardware comprising at least one live bolt capable of securing the door in a closed position after installation.
DS4. The door system according to embodiment DS3 wherein the live bolt is retained in a retracted position by a removable live bolt retainer.
DS5. The door system according to embodiment DS4 wherein the live bolt retainer is the live bolt retainer according to any of embodiments BR1 to BR-5.
DS6. The door system according to any of embodiments DS1-DS5 wherein the door comprises latch hardware comprising a deadbolt and a live bolt.
DS7. The door system according to any of embodiments DS1-DS6 wherein the hinge-side z-bar, drip cap, and latch-side z-bar comprise finished front-facing surfaces.
DS8. The door system according to any of embodiments DS1-DS7 wherein the door comprises door closer hardware contained within the thickness of the door.
DS9. The door system according to embodiment DS8 wherein the door closer hardware comprises a closer arm rotatably attached to a slider which is slideably attached to the drip cap.
DS10. The door system according to any of embodiments DS1-DS9 wherein the door and latch-side z-bar are held in a stable position relative to each other by one or more removable z-bar clips.
DS11. The door system according to embodiment DS11 wherein at least one z-bar clip is the z-bar clip according to any of embodiments ZC1 to ZC-6.
DS12. The door system according to any of embodiments DS1-DS11 comprising the assembly according to any of embodiments ZCA1, ZCA2 and ZCA3.
DS13. The door system according to any of embodiments DS1-DS12 wherein the hinge-side z-bar comprises an installation notch near its top end.
DS14. The door system according to any of embodiments DS1-DS13 wherein one or both z-bars additionally comprise screw holder mounting holes.
DS15. The door system according to embodiment DS14 wherein the screw holder mounting holes include positioning notches.
DS16. The door system according to embodiment DS14 or DS15 wherein at least one screw holder mounting hole has mounted in it a screw holder.
DS17. The door system according to embodiment DS16 wherein at least one screw holder has mounted in it a screw.
DS18. The door system according to any of embodiments DS14-DS17 wherein at least one screw holder is the screw holder according to any of embodiments SH1-SH9.
DS19. The door system according to any of embodiments DS1-DS18 comprising one or more assemblies according to any of embodiments SHA1-SHA8.
DS20. The door system according to any of embodiments DS1-DS19 wherein one or both z-bars additionally comprise z-bar extenders.
DS21. The door system according to any of embodiments DS1-DS20 wherein the door additionally comprises an expander.
DS22. The door system according to any of embodiments DS1-DS21 wherein the door is a residential storm door.
Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and principles of this disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth hereinabove.
This application claims priority to U.S. Provisional Patent Application No. 62/724,327, filed Aug. 29, 2018, entitled “READY TO INSTALL DOOR SYSTEM,” of which is incorporated by reference herein, in the entirety and for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62724327 | Aug 2018 | US |
