Static structures (e.g. – buildings) – Openwork; e.g. – truss – trellis – grille – screen – frame – or... – Outside corner or peripherally bordered
Reexamination Certificate
1999-11-22
2001-10-02
Callo, Laura A. (Department: 3635)
Static structures (e.g., buildings)
Openwork; e.g., truss, trellis, grille, screen, frame, or...
Outside corner or peripherally bordered
C052S211000, C052S716800, C052S717010, C052S717050, C052S749100, C052S749100, C049S504000
Reexamination Certificate
active
06295779
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates generally to frame members, and more to a maintenance free composite frame member that includes a structural shell with an underlying core and does not require the extensive shaping, molding and waste of conventional wooden frames, such as may be used on doors and windows, and especially on exterior door frames.
BACKGROUND AND SUMMARY OF THE INVENTION
Conventional door frames, especially exterior door frames, are formed from lumber, such as ponderosa pine. These frames have been the industry standard for years, however, as discussed below, require time-, labor- and waste-intensive steps when compared to the invented composite door frame described herein. Furthermore, conventional frames have inherent weaknesses and security concerns on account of their materials of construction.
By way of background, it should be understood that door frames have four principle components. The first two are a pair of elongate jambs, which extend vertically in a side-by-side, opposed relationship to each other to define the side walls of a cavity into which a door is hung. The other two are a header that spans the distance between the upper regions of the jambs to connect the jambs and define the top wall of the cavity, and a sill that spans the distance between the lower regions of the jambs to define the bottom wall of the cavity. Typically, the jambs and header have the same, or substantially the same, cross-sectional configuration. The sill usually is inclined as it extends inwardly from the exterior of the wall within which the frame is installed. A door is “hung” or mounted, via hinges, on one jamb, and includes a lock or clasp that engages a corresponding socket on the other jamb. As used herein, the jamb on which the door is mounted is referred to as the door-side jamb, and the jamb that is engaged by the door's lock or clasp is referred to as the lock-side jamb.
The header and jambs of a conventional frame typically have the cross-sectional configuration shown in
FIG. 1. A
portion of a jamb is indicated generally at
10
in FIG.
1
. As discussed, however, the header and jambs typically have the same cross-sectional configuration. Jamb
10
includes a base member
12
that is mounted within an opening in a wall of the building, house or other structure. Base member
12
includes a lower surface
14
that is mounted against the portion of the wall that defines the opening, and exterior and interior surfaces
16
and
18
, respectively, that face in the direction of the corresponding exterior and interior surfaces of the wall. As discussed, base member
12
is formed from lumber through a process described subsequently. Member
12
includes a stop region
20
, which selectively engages the door and defines the forward limit to which the door may pivot in the direction of the exterior of the wall. Member
12
also defines a rabbetted or removed region
22
through which the door passes before and while in engagement with stop region
20
.
Each jamb typically includes some form of weather stripping
24
that is secured to stop region
20
. In
FIG. 1
, weather stripping
24
is inserted within a channel
26
carved within stop region
20
. The jambs and header may also include brickmold, which is mounted on exterior surface
16
and extends laterally beyond the frame to overlap a portion of the exterior surface of the wall forming the opening for the frame. As shown in the portion of the lock-side jamb shown in
FIG. 1
, the jamb typically includes at least to one socket with which portions of the door's lock are inserted to prevent selectively the door from being opened. As shown, jamb portion
10
includes a pair of sockets
28
and
29
, which are configured to receive bolts from a standard door lock and a deadbolt lock.
While this configuration has been the industry standard for years and seems safe enough, it offers only minimal security to a determined intruder. The principle reason for this lack of security is due to the lumber which is used to form the conventional exterior door frame. Because sockets
28
and
29
are mounted a standardized distance away from stop member
20
, there is only a narrow portion of base member
12
between the sockets and interior surface
18
of the jamb. Furthermore, because the grain of the lumber extends generally along the length of the jamb, the jamb is prone to splitting or shattering in the direction of the grain. These combined factors contribute to a frame which may be relatively easily broken or split by forcing, and most commonly kicking, the door inwardly in the general vicinity of where the lock engages the jamb's sockets.
Another problem with conventional exterior door frames is the way even treated lumber deteriorates when exposed to rain, extreme temperatures, snow, insects, etc., over a prolonged period of time. Wood exterior frames tend to splinter and chip over time, as well as when bumped or otherwise struck during use. Furthermore, when lumber gets wet, it expands. Therefore, conventional frames tend to deform and expand into the opening when water penetrates the weather-treating, if any, on the frame. Furthermore, once water contacts any portion of the lumber, it wicks along the wood to to contact and thereby deform or begin deteriorating adjacent regions. Attempts have been made to wrap portions of the frames with a thin, paper-like layer of weather resistant material, but this has not proven to be a sufficient remedy for this problem over time. While this wrapping or capping process may extend the life of the frame, it still requires the time and labor-intensive process to form the underlying lumber construction, and furthermore lacks sufficient strength and structure to protect and support the rest of the fame. Therefore, there remains a need to protect a conventional frame from the elements, as well as from being struck by individuals or other objects.
An additional problem with conventional frames is the significant time-, labor- and waste-intensive steps needed to manufacture the frame. As an initial step, a tree is chopped down, delimbed, debarked and cut into elongate strips of lumber. During this initial step, approximately twenty-five percent, or more, of the original wood is wasted. The produced lumber predominately is what is referred to as “shop-grade” lumber, in that it is rough and contains knots and other irregularities. Therefore, the next step is to cut out the knots and other irregular areas from the lumber and then fingerjoint the remaining pieces back together. At this point, the lumber is in elongate lengths that are substantially free or “clear” of knots and other defects.
The lumber is next fed through a molder, which shapes the lumber into the cross-sectional configuration shown in FIG.
1
. At this point, approximately forty or more percent of the remaining wood has been discarded or otherwise removed from the original lengths of lumber. Next, notches
26
are carved into the stop regions of the strips, the strips are cut to length and the ends are notched with a double end tenoner so that the jambs and header will smoothly mate with each other. The lengths of molded lumber are subsequently primed, so that they may be later painted, and weathertreated, to slow the deterioration of the frame from exposure to rain, snow and other elements. Finally, the frame is assembled, weather stripping is secured to the jambs, sockets are drilled in one jamb to receive portions of a lock, and a door is hung on the other jamb.
This process is not only slow and labor-intensive, but as discussed above, also is extremely wasteful, raising environmental as well as other cost and efficiency concerns. Although a number of exterior door frames are known in the prior art such frames are unsatisfactory due to their failure to address and satisfy all of the concerns listed above.
The present invention overcomes these problems by providing a composite exterior frame member, such as may be used to form door and window frames. Each member includes a core formed fr
Callo Laura A.
Kolisch Hartwell Dickinson McCormack & Heuser, PC
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