Static structures (e.g. – buildings) – Framing to receive door – doorjamb – or window sash – Architrave; i.e. – finish strip on floor – ceiling – or wall...
Reexamination Certificate
2001-07-10
2004-07-20
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Framing to receive door, doorjamb, or window sash
Architrave; i.e., finish strip on floor, ceiling, or wall...
C052S204540, C052S717010, C049S467000, C049S471000, C049S476100, C049S483100, C049S489100, C049S490100, C049S504000, C160S092000
Reexamination Certificate
active
06763639
ABSTRACT:
TECHNICAL FIELD
This invention relates generally to entryway systems for homes and commercial buildings an more specifically to door frame assemblies incorporating continuous thresholds to which vertically extending jambs and perhaps mull posts are attached.
BACKGROUND
Entryway systems used in building construction generally include a pair of vertically extending door jambs and a head jamb that frame the entryway and receive a hinged door. An elongated threshold assembly is attached at its ends to the bottoms of the door jambs and spans the bottom of the entryway. Many modern threshold assemblies include an extruded aluminum frame having an upwardly open channel from which a sill slopes outwardly and downwardly. A threshold cap, which may be made of plastic or wood, is disposed in the upwardly open channel and underlies a closed door mounted of the entryway. The threshold cap usually is vertically adjustable within its channel to engage and form a seal with a flexible sweep attached to the bottom of the door.
Some entryways include sidelights that flank the door on one or both sides thereof. In such sidelight entryways, mullions or mull posts rest on and extend vertically from the top of the threshold assembly to the head jamb of the entryway. The mull posts along with the jambs and head jamb define the door opening or openings and the sidelight openings of the entryway. Many variations of this basic theme such as, for example, patio door entryways, inswing entryways, and outswing entryways are available to accommodate an equal number of variations of entryway designs.
Traditionally, the bottoms of door jambs, which usually are made of wood, are matted and attached to the ends of the threshold assembly by milling a specially shaped angled jamb haunch or tenon in the bottoms of the jambs and fitting and stapling or screwing the bottoms of the jambs to the assembly. A portion of the haunch overlaps and sits atop the sloped sill of the threshold assembly. The problems with this traditional construction technique are many. For instance, since virtually every brand and style of threshold assembly has a different cross-sectional profile, the jamb haunches in each case must be precisely and specially milled to fit the profile of the particular threshold assembly to which they are to be attached. This means that pre-hangers must own and operate expensive and accurate milling machinery and must maintain a number of different shaped milling cutters to accommodate the various configurations of threshold assemblies. This is also true for the bottoms of mull posts, which must be provided with an angled bottom cut specially shaped to rest atop the sloped sill of the threshold assembly.
Another problem with traditional entryway construction techniques relates to the fact that the end grain of the wooden jambs and mull posts rests directly on the sub-floor and/or sill deck. Thus, moisture from rainwater and the like that may seep or form beneath the ends of the jambs and mull posts wicks into the wood of these components causing rot and decay. A further problem is that water that may seep under the threshold cap of the assembly and into the upwardly open channel in which it resides tends to migrate to and puddle at the ends of the channel against the bottom portions of the wooden jambs. There it gradually soaks into the wood of the jambs, also causing eventual rot and deterioration.
Thus, a need exists for an improved entryway system that addresses and solves the problems and shortcomings of the prior art. Such an entryway system should eliminate the need for specially milled jambs and mull posts in order to fit these elements to the wide variety of available threshold assembly profiles, should eliminate the rotting and deterioration that typically occurs at the bottoms of jambs and mull posts where they meet the threshold assembly, and should provide for the efficient draining away of water that may seep beneath the threshold cap of the threshold assembly or otherwise form or collect in the upwardly open channel of the threshold. In addition, the system should provide for standardization of jamb and mull post lengths and should accommodate jambs and mull posts with simple square cut bottom ends. Finally, the system should provide for simple, efficient, and accurate assembly by a pre-hanger and should present an aesthetically pleasing appearance that is appealing to a homeowner. It is to the provision of such an entryway system that the present invention is primarily directed.
SUMMARY OF THE INVENTION
Briefly described, the present invention, in one preferred embodiment thereof, comprises an improved entryway system that eliminates the problems with traditional prior art entryways and entryway construction techniques. The entryway system comprises an elongated continuous threshold assembly that preferably is made of extruded aluminum formed with an upwardly open channel from which a downwardly and outwardly sloping sill extends. A vertically adjustable threshold cap is disposed in at least a portion of the channel for underlying a closed door of the entryway.
A jamb boot is attached to each end of the threshold assembly for receiving and mating with the bottom of a respective one of the vertically extending door jambs of the entryway. Each jamb boot preferably is made of injection molded plastic and is pre-formed with an angled tenon or haunch that is configured precisely to fit and rest on the sill deck of the particular threshold assembly to which the jamb boot is attached. In this regard, the jamb boot resembles the milled bottom end of a traditional wooden jamb. Each jamb boot preferably is shaped with a cross-sectional profile that corresponds essentially to the cross-sectional profile of a door jamb and attached brick mold. However, the jamb boots may be formed with a profile that does not include a brick mold portion if desired. Each jamb boot extends upwardly a short distance from the end of the end of the threshold assembly and terminates in an upper face or surface. The upper surfaces of the jamb boots are substantially flat (although calking grooves or other features may be formed in the upper surfaces if desired) and are formed to lie in a horizontal plane or planes with the threshold assembly resting on a level surface.
The jamb boots of this invention are pre-attached and sealed with silicone sealant or other appropriate adhesive to the ends of the threshold assembly by a threshold assembly manufacturer before shipping the threshold assembly to a pre-hanger for incorporation into a completed entryway system. At the pre-hanger's facilities, wooden jambs are prepared for attachment to the threshold assembly simply by square cutting the bottoms of the jambs. The square-cut jamb bottoms are then mated to the substantially flat top surface of the corresponding jamb boots, and attached to the boots preferably with screws extending through the bottom of the jamb boots and into the ends of the jambs. In one embodiment, strategically positioned alignment nibs and a step are formed in the upper surface of the jamb boots to align the bottoms of the jambs precisely with their jamb boots before the jambs are attached. In this way, proper alignment is essentially automatic and a pre-hanger may assemble an entryway quickly and efficiently without special jigs and on a simple horizontal assembly table.
In one embodiment, each of the jamb boots is formed with an internal drain channel that receives collected water from the ends of the upwardly open channel of the sill and directs the water to the outside face of the jamb boot, where the water drains away from the entryway. Thus, water that may seep or form beneath the threshold cap is harmlessly drained away and does not collect beneath the threshold cap. The jamb boots also may be formed without this draining feature if desired.
The entryway system of the invention also includes injection molded plastic mull post boots for use with sidelight or other types of entryways where mull posts are employed. The mull post boots also are pre-formed
Bennett Joel S.
Massey Victor T.
Endura Products, Inc.
Friedman Carl D.
Horton Yvonne M.
Womble Carlyle Sandridge & Rice PLLC
LandOfFree
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