Covers for door jambs and mullions

• US 20030145538A1
• Filed: 03/28/2002
• Published: 08/07/2003
• Est. Priority Date: 02/07/2002
• Status: Active Grant

• Current Assignee: Bay Industries Inc (AWS/GB Corp.)
• Original Assignee: Bay Industries Inc (AWS/GB Corp.)
• Inventors: Kerscher, Lawrence Frank
• Granted Patent: US 7,111,433 B2
• Time in Patent Office: Days
• US Class Current: 52/212
• CPC Class Codes: E06B 1/34 Coverings, e.g. protecting against weather, for decorative purposes
• CPC Class Codes: E06B 1/62 Tightening or covering joints between the border of openings and the frame or between contiguous framesE06B1/34 takes precedence
• CPC Class Codes: E06B 1/68 by profiled external parts
• CPC Class Codes: E06B 2001/622 especially adapted for door frames; Joint covering devices where the wall surface is parallel to the adjacent door or window frame part

Abstract

Metal cladding as jamb cover assemblies and mullion cover assemblies, for door frames and mullions, using extrusions as cladding over substrates. A jamb cover assembly includes a jamb plate, a nosing, and a nailing fin. The nailing fin extends from a distal side of the assembly. Accordingly, the frame can be secured in a rough opening of a building with the nosing assembled to the jamb plate, and using the nailing fin for the securement, without any assembly or disassembly of the frame at the construction site. Regarding the mullion cover assembly, first and second jamb plates are on opposing sides of a mullion substrate. A mullion nosing is assembled to the jamb plates, and bridges the jamb plates to join together the two jamb plates and the nosing, to provide complete overlayment of the outer surface of the mullion substrate and to space the front panel of the nosing from the outer surface of the substrate.

Claims

1. An elongate jamb plate for mounting on an elongate jamb substrate of a door frame, said jamb plate comprising:

(a) a main side panel for covering at least a major portion of a side surface of such jamb substrate, along at least a major portion of a length of such jamb substrate; and

(b) an outer panel for extending along a least a major portion of the length of such jamb substrate, and configured to extend at an angle transverse to said main side panel, and away from said main side panel and over an outer surface of such jamb substrate, said outer panel bearing mounting structure adapted to mount said outer panel to an elongate nosing, said outer panel being devoid of structure outwardly of said mounting structure for mounting said jamb plate to a framing member of a building to which such door frame is to be mounted.

2. An elongate jamb plate as in claim 1, and including said mounting structure comprising first and second spaced legs, extending outwardly from said outer panel, and including locking structure for assisting in locking such nosing to said jamb plate.

3. An elongate jamb plate as in claim 2, the extension of said outer panel, away from said main side panel, ending proximate an outermost one of said legs.

4. An elongate jamb plate as in claim 1 wherein said jamb plate comprises an aluminum extrusion having nominal profile thicknesses of about 0.06 inch.

5. An elongate nosing for mounting to an elongate jamb plate, wherein such elongate jamb plate is designed and configured to be mounted on an elongate jamb substrate of a door frame, wherein such elongate jamb plate comprises a main side panel for covering at least a major portion of a side surface of such jamb substrate, along at least a major portion of a length of such jamb substrate, and wherein such elongate jamb plate further comprises an outer panel for extending along a least a major portion of the length of such jamb substrate, such outer panel being configured to extend at an angle transverse to such main side panel, and away from such main side panel and over the outer surface of such jamb substrate, such outer panel bearing a first mounting structure, said elongate nosing comprising

a second mounting structure, designed and configured to cooperatively mount to such first mounting structure of such jamb plate, thereby to mount said nosing to such jamb plate, said nosing, when mounted to such jamb plate, extending away from such main side panel of such jamb plate to a distal side of said nosing, said nosing comprising a mounting fin kerf proximate the distal side of said nosing and away from such main side panel of such jamb plate.

6. An elongate nosing as in claim 5, said nosing comprising first and second spaced legs, connected at spaced locations of said legs to a front panel of said nosing, said second mounting structure being disposed on said legs.

7. An elongate nosing as in claim 5, and including a mounting fin in said mounting fin kerf.

8. An elongate nosing as in claim 5, said mounting fin comprising a polymeric mounting fin.

9. An elongate nosing as in claim 8 wherein said polymeric mounting fin is deflectable toward such main side panel of such jamb plate, and into proximity with a such jamb substrate when said elongate nosing is mounted to a such jamb plate which is mounted to a such jamb substrate.

10. An elongate nosing as in claim 5 wherein said elongate nosing comprises an aluminum extrusion having nominal profile thicknesses of about 0.06 inch.

11. In combination, an elongate jamb plate, and an elongate nosing for mounting to said elongate jamb plate,

said elongate jamb plate comprising

(a) a main side panel for covering at least a major portion of a side surface of a jamb substrate, along at least a major portion of a length of such jamb substrate, and

(b) an outer panel extending along at least a major portion of the length of such jamb substrate, and extending at an angle transverse to said main side panel, and extending away from said main side panel and over the outer surface of such jamb substrate, said outer panel comprising a first mounting structure,

said elongate nosing comprising

(c) a second mounting structure, designed and configured to cooperatively engage said first mounting structure of said jamb plate, thereby to mount said nosing and said jamb plate to each other, said nosing, when so mounted to said jamb plate, extending in a direction away from said main side panel of said jamb plate to a distal side of said nosing,

the combination of said jamb plate and said nosing, when so mounted to each other, comprising a mounting fin kerf in a region from proximate the distal side of said nosing to proximate said first mounting structure.

12. A combination as in claim 11, said mounting fin kerf being disposed on said nosing.

13. A combination as in claim 11, said mounting fin kerf being disposed on said outer panel of said jamb plate.

14. A combination as in claim 11, and including a mounting fin in said mounting fin kerf and extending outwardly beyond the distal side of said nosing and away from said main side panel of said jamb plate.

15. A combination as in claim 11, said first mounting structure comprising first and second studs extending from said outer panel of said jamb plate.

16. A combination as in claim 11, said nosing comprising first and second spaced legs, connected at spaced locations of said legs to a front panel of said nosing, said second mounting structure being disposed on said legs.

17. A combination as in claim 11 wherein said second mounting structure on said nosing can snap lock to said first mounting structure on said outer panel of said jamb plate.

18. A combination as in claim 15 wherein said second mounting structure on said nosing can snap lock to said studs.

19. A combination as in claim 11, and including a mounting fin in said mounting fin kerf, said mounting fin comprising a polymeric fin mounted in said combination of said jamb plate and said nosing at said mounting fin kerf.

20. A combination as in claim 12, and including a mounting fin in said mounting fin kerf, said mounting fin comprising a polymeric fin mounted in said combination of said jamb plate and said nosing at said mounting fin kerf.

21. A combination as in claim 13, and including a mounting fin in said mounting fin kerf, said mounting fin comprising a polymeric fin mounted in said combination of said jamb plate and said nosing at said mounting fin kerf.

22. A combination as in claim 19 wherein said mounting fin is deflectable toward said main side panel of said jamb plate, and into proximity with such jamb substrate when said elongate nosing is mounted to said jamb plate and said jamb plate is mounted to a such jamb substrate.

23. A combination as in claim 20 wherein said mounting fin is deflectable toward said main side panel of said jamb plate, and into proximity with such jamb substrate when said elongate nosing is mounted to said jamb plate and said jamb plate is mounted to a such jamb substrate.

24. A combination as in claim 21 wherein said mounting fin is deflectable toward said main side panel of said jamb plate, and into proximity with such jamb substrate when said elongate nosing is mounted to said jamb plate and said jamb plate is mounted to a such jamb substrate.

25. A combination as in claim 11 wherein said jamb plate comprises an aluminum extrusion having nominal profile thicknesses of about 0.06 inch.

26. A combination as in claim 11 wherein said nosing comprises an aluminum extrusion having nominal profile thicknesses of about 0.06 inch.

27. A pre-assembled door frame for assembly into a building at an opening in such building, said pre-assembled door frame comprising:

(a) an elongate jamb substrate having a length, an outer surface for facing outwardly away from such building when said door frame is assembled to such building, and a side surface for facing across such opening whereat said door frame is assembled to such building; and

(b) a jamb cover assembly on said elongate jamb substrate, said jamb cover assembly comprising

(i) an elongate jamb plate comprising

a main side panel covering at least a major portion of the side surface of said substrate, along at least a major portion of the length of said substrate, and

an outer panel extending along at least a major portion of the length of said substrate, and extending at an angle transverse to said main side panel, and extending away from said main side panel and over the outer surface of said jamb substrate, said outer panel comprising a first mounting structure, and

(ii) an elongate nosing comprising a second mounting structure, engaged with said first mounting structure on said outer panel of said jamb plate and thereby mounting said nosing and said jamb plate to each other, said nosing extending in a direction away from said main side panel to a distal side of said nosing,

said jamb cover assembly comprising a mounting fin extending outwardly beyond the distal side of said nosing and in a direction away from said main side panel of said jamb plate, said mounting fin being sized and configured thereby to enable mounting said jamb cover assembly to a framing member of such building at an outwardly-facing surface of such framing member while said nosing is mounted to said jamb plate.

28. A pre-assembled door frame as in claim 27, and including a mounting fin kerf on one of said nosing and said jamb plate, said mounting fin being received in said mounting fin kerf.

29. A pre-assembled door frame as in claim 27, and including a mounting fin kerf on said nosing, said mounting fin being received in said mounting fin kerf.

30. A pre-assembled door frame as in claim 27, and including a mounting fin kerf proximate the distal side of said nosing, said mounting fin being received in said mounting fin kerf.

31. A pre-assembled door frame as in claim 27, said first mounting structure comprising first and second studs extending from said outer panel of said jamb plate.

32. A pre-assembled door frame as in claim 27, said nosing comprising first and second spaced legs, connected at spaced locations of said legs to a front panel of said nosing, said second mounting structure being disposed on said legs.

33. A pre-assembled door frame as in claim 27 wherein said second mounting structure on said nosing snap locks to said first mounting structure on said outer panel of said jamb plate.

34. A pre-assembled door frame as in claim 27 wherein said second mounting structure on said nosing snap locks to said studs.

35. A pre-assembled door frame as in claim 27, said outer panel of said jamb plate being in surface-to-surface relationship with the outer surface of said jamb substrate.

36. A pre-assembled door frame as in claim 28, said mounting fin comprising a polymeric fin mounted in said jamb cover assembly at said mounting fin kerf.

37. A pre-assembled door frame as in claim 29, said mounting fin comprising a polymeric fin mounted in said jamb cover assembly at said mounting fin kerf.

38. A pre-assembled door frame as in claim 30, said mounting fin comprising a polymeric fin mounted in said jamb cover assembly at said mounting fin kerf.

39. A pre-assembled door frame as in claim 36 wherein said mounting fin is deflectable so as to be folded against said jamb substrate.

40. A pre-assembled door frame as in claim 37 wherein said mounting fin is deflectable so as to be folded against said jamb substrate.

41. A pre-assembled door frame as in claim 38 wherein said mounting fin is deflectable so as to be folded against said jamb substrate.

42. A pre-assembled door frame as in claim 27 wherein said jamb plate comprises an aluminum extrusion having nominal profile thicknesses of about 0.06 inch.

43. A pre-assembled door frame as in claim 27 wherein said nosing comprises an aluminum extrusion having nominal profile thicknesses of about 0.06 inch.

44. A cladded mullion assembly, comprising:

(a) a mullion substrate having a length, first and second opposing side surfaces facing in opposing directions, generally along an outer surface of a building when said cladded mullion assembly is installed on such building, and an outer surface facing outwardly from such building when said cladded mullion assembly is installed on such building;

(b) a first elongate jamb plate comprising a first main side panel extending along at least a major portion of the first side surface of said mullion substrate, along at least a major portion of the length of said mullion substrate, said first elongate jamb plate further comprising a first outer panel extending along at least a major portion of the length of said mullion substrate, and extending at an angle transverse to said first main side panel, and extending away from said first main side panel and over the outer surface of said mullion substrate, said first outer panel comprising a first mounting structure;

(c) a second elongate jamb plate comprising a second main side panel extending along at least a major portion of the second side surface of said mullion substrate, along at least a major portion of the length of said mullion substrate, said second elongate jamb plate further comprising a second outer panel extending along at least a major portion of the length of said mullion substrate, and extending at an angle transverse to said second main side panel, and extending away from said second main side panel and over the outer surface of said mullion substrate toward said first outer panel of said first jamb plate, said second outer panel comprising a second mounting structure; and

(d) an elongate nosing comprising a third mounting structure engaged with said first and second mounting structures on said first and second jamb plates and thereby mounting said nosing to said first and second jamb plates such that said nosing bridges said jamb plates, thereby locking together the combination of said nosing and said first and second jamb plates proximate the outer surface of said mullion substrate.

45. A cladded mullion assembly as in claim 44, said nosing comprising a front panel spaced from said outer panels of said first and second jamb plates.

46. A cladded mullion assembly as in claim 44 wherein said jamb plates and said nosing comprise aluminum extrusions.

47. A cladded mullion assembly as in claim 46 wherein said aluminum extrusions have nominal profile thicknesses of about 0.06 inch

48. A cladded mullion assembly as in claim 46 wherein said first and second outer panels of the respective said first and second jamb plates are in surface-to surface relationship with the outer surface of said mullion substrate.

49. A method of installing a door frame in a door opening in a building, comprising:

(a) at an off-site location, assembling the door frame comprising

(i) assembling together left, right, and top frame substrate members, each having a side surface facing inwardly of the opening in the building when installed in the building and an outer surface facing outwardly away from the building when installed in the building, thereby to make a door frame precursor having left, right, and top frame elements,

(ii) installing, on the substrate members, elongate jamb plates wherein each jamb plate comprises a main side panel covering at least a major portion of the side surface of the respective substrate member, and an outer panel extending along a major portion of the outer surface of the respective substrate member,

(iii) mounting nosings on the outer panels of the jamb plates, and

(iv) at at least one of the left, right, and top frame elements, assembling a mounting fin to one of the respective jamb plate and the respective nosing, the mounting fin extending outwardly away from the main side surface and away from both the nosing and the jamb plate,

(b) transporting the so-assembled door frame to the building site; and

(c) installing the so fully assembled door frame to the building, including securing the mounting fin to a building frame member while the respective nosing is installed on the respective jamb plate.

50. A method as in claim 49, including assembling a mounting fin to each of the left, right, and top frame elements such that the respective mounting fins extend outwardly, away from the main side panels of the jamb plates and generally in directions consistent with the outer panels of the jamb plates when the door frame is assembled to the building.

51. A method as in claim 49, the mounting fin comprising a flexible polymeric mounting fin.

52. A method as in claim 50, the mounting fin comprising a flexible polymeric mounting fin.