Arch jamb leg interface

Abstract

There is provided an arch assembly comprising a pair of opposing vertical jamb members each including internal and external surfaces and a top surface at distal ends thereof. The external surfaces thereof preferably abut opposing parallel sides of a door frame. An arch jamb is interposed between the vertical jamb members. The arch jamb defines a curvature, opposing connective ends, and an upper surface. The connective ends each include a leg interface defining first and second vertical faces, and a horizontal face interposed therebetween. The first vertical face is configured to mate with the interior surface of the respective vertical jamb member. The horizontal face is configured to mate with the top surface of the respective vertical jamb member. The second vertical face is configured to engage the respective opposing parallel side of the door frame. The engagement of the leg interface provides structural stability of the arch jamb.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefits of U.S. Provisional Patent Application No. 60/798,022, filed May 5, 2006, the entire contents of which are expressly incorporated herein.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND

The present invention relates generally to door framing assemblies, and more particular, to an arched jamb assembly utilizing unique connective geometry to better support loads and handle stresses.

During the early stages of construction, each of the walls and wall openings of a building, such as a house, must be properly framed in order to support the loads that will be placed thereon. While many diverse designs have been created to meet the tastes and needs of consumers, each design must meet the strict structural requirements for construction.

The standard doorway is rectangular in shape. However, other shapes for doorways and doors have been developed. For example, many houses incorporate the use of taller than standard doors and doorways. In addition, arched doors and arched doorways have also become popular in recent years. Features such as these are commonly utilized to make the house feel more spacious and beautiful. Many builders have developed unique methods and products for creating these arched doorways and arched door frame assemblies.

For example, prior art arched door jamb assemblies 10 typically included specially cut opposing side jambs 12 and a central arch jamb 14. The assemblies 10 were formed by creating an angular notch 16 in upper end portions 18 of the side jambs 12, as illustrated in FIG. 1. Opposing ends 20 of the central arch jamb 14 are then inserted into the notches 16 of the respective ones of the side jambs 12 to create the arched door jamb assembly 10. Other fasteners and/or adhesives 22 may then be utilized to secure the arch jamb 14 in place. This method and assembly 10 is very difficult because it requires the carefully made angular notch 16 in the opposing door jambs, as well as very exact measuring and execution in order to ensure that the notches 16 are properly cut at the correct location. Further, the strength of the side jambs 12 is weakened where the angular notch 16 is cut into the side jambs 12, thus lessening the structural integrity of the arched door jamb assembly 10.

As shown in FIG. 2, another prior art arched door jamb assembly 10 connects the arch jamb 14 to the distal top end 24 of opposing side jambs 12. In this assembly 10, rectangular cuts 26 are made to both the arch jamb 14 and to the side jambs 12. Although this particular method of creating the arched door jamb assembly 10 may have reduced some of the work associated with measuring and cutting the side jambs 12 relative to the assembly 10 shown in FIG. 1, it nevertheless requires that the cuts 26 made to the arch jamb 14 exactly match the notches 16 made in the door jamb side members. Thus, as before, the assembly 10 and construction of the arched door jamb assembly 10 is made difficult because of the measuring and cutting requirements. Further, if any vertical shifting occurs, a gap will develop between the opposing ends 20 of the arch jamb 14 and the distal top ends 24 of the side jambs 12. This result would not only be aesthetically unsightly, but may also produce undesirable structural problems.

Finally, in yet another method and assembly 10, as illustrated in FIG. 3, the concept of cutting only the opposing ends 20 of the arch jamb 14 was developed. This design alleviated the vertical shifting problem of the assembly 10 in FIG. 2, which would result in the aforementioned gap between the opposing ends 20 of the arch jamb 14 and the distal top ends 24 of the side jambs 12. In this method, the distal top end 24 of the door side jambs 12 are left uncut (either in an original state or cut to be a rectangular parallelepiped in shape), in a substantially perpendicular orientation, as shown in FIG. 3. In order to fit the arch jamb 14 to the distal top ends 24 of the opposing side jambs 12, angled cuts 28 are made to the opposing ends 20 of the arch jamb 14. While this method somewhat reduced the cutting and measurement requirements, other disadvantages have been noted. For example, the arch door jamb member may have the tendency to split or crack when a load is placed thereon. For example, if a downward force is exerted at an apex 30 of the arch jamb 14, it may cause the arch jamb 14 to tend to expand horizontally. This expansive downward force is resisted only by a lower portion 32 of the opposing end 20 of the arch jamb 14, which is formed by the angled cut 28. Thus, the lower portion 32 may tend to transfer the expansive force of the arch jamb 14 in a horizontal direction through the distal top end 24 of the side jamb 12. As a result, a stress concentration in a corner 34 of the angled cut 28 may be created. The stress concentration may then cause high local stresses which may result in the splitting or splintering of the arch jamb 14 along its length or additionally, the simple fracture of the lower portion 32 of the opposing end 20 of the arch jamb 14. In either case, the arch jamb 14 may need to be replaced.

In addition to the difficulties mentioned above with respect to each of the prior art arch door jamb assemblies 10, all of the prior art techniques have one further disadvantage as shown in FIG. 4: when used with a corner bead 38, such as drywall bull nose corner bead, the side jamb 12 of each assembly 10 meets the arch jamb 14 and forms an obstruction 36 that protrudes beyond the corner bead 38 and complicates mating between the assembly 10 and the corner bead 38. The obstruction 36 may be part of the side jamb 12 or the arch jamb 14 (depending on the configuration of the assembly 10). In many cases, as is known in the art, the corner bead 38 may be used in lieu of door casing to provide an attractive finish to the assembly 10 and the doorway. The corner bead 38 defines an inner surface 40, and the corner bead 38 should extend continuously about the arch jamb 14 and side jambs 12 of the assembly 10 with the inner surface 40 of the corner bead 38 being substantially mated to an exterior surface 42 of the assembly 10. However, in order to achieve proper mating between the inner surface 40 of the corner bead 38 and the exterior surface 42 of the assembly 10, the obstruction 36 must be removed from the assembly 10. The time and expense of removing the obstruction 36 from the assembly 10 may be costly and labor intensive. However, in order to achieve proper mating between the inner surface 40 of the corner bead 38 and the exterior surface 42 of the assembly 10, the labor and expense must be made. Thus, either the opposing end 20 of the arch jamb 14 or the distal top end 24 of the side jamb 12 must be carefully cut or machined in order for the obstruction 36 to be removed and for the assembly 10 to properly fit within the corner bead 38.

Therefore, there is a need in the art for an arched door jamb assembly that provides for easy measurement and cutting as well as easy installation. Further, there is a need in the art for an arched door jamb assembly that does not produce a visible gap intermediate the opposing end of the arch jamb and the distal top end 24 of the side jamb in the event of vertical shifting. Additionally, there is a need in the art for an arched door jamb assembly that eliminates the need of additional cutting to remove obstructions in order for the assembly to properly and easily mate with corner bead. Furthermore, there is a need in the art for an arch door jamb assembly that tends to balance the forces that may be exerted on the arch jamb. In particular, there is a need in the art for an improved arched door jamb assembly that tends to eliminate stress concentration in the interconnection joints between the arch door jamb member and the door jamb side members.

BRIEF SUMMARY

A door jamb arch assembly is provided for obtaining substantial structural and aesthetic improvements over prior art arched door jamb assemblies. Embodiments of the present invention may be used with a door frame, although not required. The door frame may have opposing parallel sides and a horizontal support. The opposing parallel sides defining top ends, and the horizontal support is interposed between the opposing parallel sides at the top ends thereof.

The arch assembly includes a pair of opposing vertical jamb members and an arch jamb interposed therebetween. The vertical jamb members each include internal and external surfaces and a top surface at distal ends thereof. The external surfaces thereof preferably abut the opposing parallel sides of the door frame. The vertical jamb members each further define a jamb width and a jamb depth.

The arched jamb member defines a curvature, opposing connective ends, and an upper surface. The connective ends include a leg interface that defines first and second vertical faces and a horizontal face interposed therebetween. The first vertical face of the leg interface is configured to mate with the interior surface of the respective vertical jamb member. The horizontal face of the leg interface is configured to mate with the top surface of the respective vertical jamb member. Finally, the second vertical face of the leg interface is configured to engage the respective opposing parallel side of the door frame. According to an aspect of the present invention, the engagement of the leg interface thus provides for enhanced structural stability of the arch jamb.

In addition, according to another aspect of the present invention, the engagement of the connective end to the vertical jamb member creates a slip joint. The slip joint is advantageous in that it may conceal any gap between the connective end and the vertical jamb member that may result in slight or substantial, intentional or unexpected vertical displacements. In this regard any gap between the top surface of the vertical jamb member and the horizontal face of the leg interface is concealed by the first vertical face of the leg interface. Further, the continuing engagement of the second vertical face with the opposing parallel side of the door frame tends to ensure the continuing structural stability of the assembly during such vertical shifting.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:

FIG. 1 is a front view of a prior art arched door jamb assembly showing an arch jamb connected to opposing side jambs utilizing a notch;

FIG. 1A is a front view of a connective joint of the arched door jamb assembly of FIG. 1;

FIG. 2 is a front view of another prior art arched door jamb assembly showing an arch jamb connected to opposing side jambs wherein cuts are made to opposing ends of the arch jamb and to distal top ends of the side jambs;

FIG. 2A is a front view of a connective joint of the arched door jamb assembly of FIG. 2;

FIG. 3 is a front view of yet another prior art arched door jamb assembly showing an arch jamb connected to opposing side jambs utilizing an angled cut into the opposing ends of the arch jamb;

FIG. 3A is a front view of a connective joint of the arched door jamb assembly of FIG. 3;

FIG. 4 is an exemplary enlarged front view of a connective joint of the prior art arched door jamb assemblies illustrating an obstruction that prevents the assembly from properly mating with a corner bead;

FIG. 5 is an enlarged front view of a leg interface of a connective end of an exemplary door jamb arch assembly being mated with a corner bead and having no obstruction, according to an aspect of the present invention;

FIG. 6 is a front view of an exemplary embodiment of a door jamb arch assembly installed in a doorframe, the doorframe having opposing parallel sides and a horizontal support, the assembly having an arch jamb and opposing vertical jamb members, the arch jamb including connective ends being attached to the vertical jamb members utilizing an arch jamb leg interface;

FIG. 6A is a enlarged front view of the attachment of the connective end of the arch jamb to the vertical jamb member as shown in FIG. 6, showing engagement of the leg interface with the vertical jamb member and a parallel side of a door frame, according to an aspect of the present invention;

FIG. 7 is an enlarged front view of the leg interface of the connective end shown in FIG. 6A showing first and second vertical faces and a horizontal face interposed therebetween, according to an aspect of the present invention;

FIG. 8 is an enlarged partial side view of the connective end and the vertical jamb member of the assembly shown in FIG. 6A, according to an aspect of the present invention;

FIG. 9 is a front view of a table saw, fence, and guide fixture for machining the arch jamb to create the leg interface according to an aspect of the present invention, according to an aspect of the present invention; and

FIG. 10 is a partial front view of the leg interface illustrating a cut-out portion of a given connective end of the arch jamb that may be removed during the machining process to form the leg interface in accordance with an aspect of the present invention, according to an aspect of the present invention.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the invention only, and not for purposes of limiting the same, FIG. 6 is an illustration of a door jamb arch assembly 100 including an innovative arch jamb leg interface 102. As illustrated in FIG. 6, the door jamb arch assembly 100 comprises a pair of opposing vertical jamb members 104 and an arch jamb 106 interposed therebetween. The assembly 100 may be utilizing in a door frame 108. As indicated above, such door frames 108 may be utilized to facilitate passage through openings in walls, for example. The dimensions associated with the door frame 108 typically depend on the purposes for which the opening will be used. In some cases, the opening may be used to accommodate a door, and in other situations, the opening may simply be used to facilitate passage into an adjacent room. It will be noted the embodiments described herein may be utilized in various ways to enhance the beauty and structural integrity of any opening in the wall that incorporates an arch.

In standard construction, the door frame 108 typically includes opposing parallel sides 110 and a horizontal support 112. Nevertheless, the embodiments disclosed herein may also be used with a door frame 108 that does or does not include the horizontal support 112. Further, it is contemplated that substitutes for the opposing parallel sides 110 may be provided; the structural significance of the opposing parallel sides 110 with respect to embodiments of the present invention will be discussed further below.

The opposing parallel sides 110 are often fabricated from 2″×4″ wood studs or other comparable materials, which may be of other dimensions. The horizontal support 112 is interposed between the opposing parallel sides 110 at top ends 114 of the opposing parallel sides 110, and is typically oriented orthogonally with respect to the opposing parallel sides 110. Similar to the opposing parallel sides 110, the horizontal support 112 is typically made from 2″×4″ wood stud. The horizontal support 112 is also typically attached to the opposing parallel sides 110 utilizing common fasteners such as nails or screws. Thus, the door frame 108 typically is fabricated in the shape of a rectangle. While embodiments of the present invention may be used with only the opposing parallel sides 110, such configurations may be less common; nevertheless, the horizontal support 112 may be omitted. Finally, it is also contemplated that various other configurations for the door frame 108 may be developed that allow use for the embodiments of the present invention disclosed herein.

In fact, due to the variations in building construction, the use of the opposing parallel sides 110 and the horizontal support 112 of the door frame 108 may be obviated by implementing embodiments of the present invention. For example, the opposing vertical jamb members 104 of the door jamb arch assembly 100 may be configured to serve as the opposing parallel sides 110 of the door frame 108. Nevertheless, in preferred implementations of the embodiments discussed herein, the opposing vertical jamb members 104 abut the parallel sides 110 of the door frame 108. This embodiment is more likely considering the common practice of combining multiple 2×4's (i.e. reinforcing the parallel sides 110) on either side of the door frame 108 in order to obtain desirable strength properties. Thus, as discussed further below, the opposing parallel sides 110 of the door frame 108 may be utilized in conjunction with the arched jamb member in order to further strengthen the doorjamb arch assembly 100.

As mentioned, the door jamb arch assembly 100 comprises the pair of opposing vertical jamb members 104 and the arch jamb 106 interposed therebetween. As shown in FIG. 6, the vertical jamb members 104 each include internal and external surfaces 116, 118 and a top surface 120. According to an embodiment of the present invention, the external surfaces 118 of the vertical jamb members 104 preferably abut the opposing parallel sides 110 of the door frame 108. Indeed, according to a preferred embodiment, the entire external surface 118 of the vertical jamb member 104 abuts a respective parallel side 110 of the door frame 108.

Each vertical jamb member 104 defines a jamb width 122, as illustrated in FIG. 6A. The jamb width 122 is the length of the top surface 120 of the vertical jamb member 104. In addition, the vertical jamb member 104 may define a jamb depth 124. The jamb depth 124 may typically correspond to the thickness of the wall.

The vertical jamb members 104 are preferably fabricated from a wood material. Nevertheless, many suitable substitutes are available in the industry. For example, many types of fiber board, such as medium density fiber board, as well as numerous other materials such as metals and composites, may be used in fabricating the opposing vertical jamb members 104.

As shown in FIG. 6, the arch jamb 106 defines a curvature 126, opposing connective ends 128, and an upper surface 129. The arch jamb leg interface 102, which defines first and second vertical faces 130, 132 and a horizontal face 134 disposed intermediate the first and second vertical faces 130, 132. As shown in FIG. 6A, the first and second vertical faces 130, 132 are preferably substantially parallel to the internal and external surfaces 116, 118 of the opposing vertical jamb members 104, respectively. Furthermore, the horizontal face 134 of the leg interface 102 defines an interface horizontal width 136 and an interface depth 138. The interface horizontal width 136 is preferably sized to correspond to the jamb width 122 of the top surface 120 of the opposing vertical jamb, and the interface depth 138 should preferably likewise be sized to correspond to the jamb depth 124 of the top surface 120 of the opposing vertical jamb member 104. Finally, as shown in FIGS. 6A and 7, the first vertical face 130 of the leg interface 102 defines a first interface height 140, and the second vertical face 132 of the leg interface 102 defines a second interface height 142. The first interface height 140 should preferably be greater than the maximum distance through which the opposing connective ends 128 may be vertically displaced in order to ensure that no visible gap develops intermediate the horizontal face 134 of the leg interface 102 and the top surface 120 of the opposing vertical jamb member 104.

Referring now to FIG. 7, according to an aspect of embodiments of the present invention, the horizontal face 134 of the leg interface 102 is preferably configured to mate with the top surface 120 of the respective vertical jamb member 104. Further, the first vertical face 130 of the connective ends 128 is preferably configured to mate with the internal surface 116 of the respective vertical jamb member 104, as illustrated in FIG. 6. Thus, the first vertical face 130 of the connective end 128 of the arch jamb 106 provides a surface engagement with the internal surface 116 of the vertical jamb member 104 that allows any forces exerted laterally through the arch jamb 106 to be distributed laterally to the opposing vertical jamb member 104. Further, a potential vertical friction force between the first vertical face 130 and the internal surface 116 of the vertical jamb member 104 may serve to counteract any upward vertical force exerted relative to the arch jamb 106, thus tending to maintain steady the engagement between the first vertical face 130 of the connective end 128 and the internal surface 116 of the vertical jamb member 104.

In addition, according to another aspect of embodiments of the present invention, the second vertical face 132 of each connective end 128 is configured to engage the respective opposing parallel side 110 of the door frame 108. This unique aspect of embodiments of the present invention provides for superior structural strength of the arch jamb 106 as a result of the innovative leg interface 102, which was not present in prior art arched door jamb assemblies 10.

For example, if a downward force is exerted at an apex of the arch jamb 106, such force is transferred through the arch jamb 106 toward the opposing connective ends 128, through the leg interfaces 102 and toward the vertical jamb members 104. This force may tend to reduce the curvature 126 of the arch jamb 106 (as similarly described above in relation to FIGS. 3 and 3A). As a result, the opposing connective ends 128 may be forced horizontally outwardly with respect to each other. The first vertical faces 130 of the opposing connective ends 128 may engage the internal surface 116 of the vertical jamb member 104 and thereby resist the horizontally outward movement of the connective end 128 and thus counter the relatively downward force exerted on the arched jamb member. However, as in the illustration of FIG. 3 and 3A, a stress concentration would likely result at the connective end 128 where the horizontal face 134 intersects with the first vertical face 130. In order to alleviate this stress concentration, the second vertical face 132 engages with the opposing parallel side 110 of the door frame 108. This engagement may thus serve to mitigate the stress concentration on the connective end 128 at an intersection 144 of the horizontal face 134 and the first vertical face 130 of the connective end 128 by sharing any horizontal load that is exerted through the connective end 128. The engagement of the second vertical face 132 to the opposing parallel side 110 of the door frame 108 thus transfers the horizontal load throughout the length of the arch jamb 106 instead of having a localized stress concentration at the intersection 144 of the horizontal face 134 and the first vertical face 130. The engagement of the second vertical face 132 to the opposing parallel side 110, as well as the engagement of the first vertical face 130 with the internal surface 116 of the vertical jamb member 104, may tend to reduce the likelihood of failure of the connective ends 128 upon significant loading.

Referring now to FIG. 5, according to another advantageous aspect of the present invention, the assembly 100 does not include any obstructions as found in the prior art assemblies 10 (illustrated in FIG. 4). Therefore, the assembly 100 may be used with corner bead 38 without incurring the additional labor and expense of removing an obstruction to achieve proper mating between the external surface 118 of the jamb member 104 and the inner surface 40 of the corner bead 38, as well as between the upper surface 129 of the arch member 106 and the inner surface 40 of the corner bead 38. Thus, each connective end 128 of the arch jamb 106, as well as each opposing vertical jamb member 104 does not need to be cut or machined after assembly, as was required in the prior art assemblies 10. As mentioned above, each of the prior art arch doorjamb assemblies 10 have the disadvantage that the side jamb 12 of each assembly 10 meets the arch jamb 14 to form an obstruction 36 that protrudes beyond the corner bead 38 when being installed therein, as shown in FIG. 4. As indicated previously, the corner bead 38 typically extends continuously about the assembly 10. In order to properly mate with the inner surface 40 of the corner bead 38, the obstruction 36 needed to be removed from the assembly 10, which may require significant time and expense.

However, according to embodiments of the present invention, there is no problematic obstruction to be cut off after the assembly 100 is created. Instead, as shown in FIG. 5, the upper surface 129 of the arch member 106, the second vertical face 132 of each connective end 128, as well as the external surfaces 118 of the vertical jamb members 104, are configured to mate with exterior surface 40 of the corner bead 38. This is achieved, as explained below with reference to FIGS. 9-10, due to the manufacturing of the assembly 100. Thus, there is no need for cutting away any obstruction from the connective end 128 after creating the assembly 100. The connective end 128 may therefore be properly formed prior to assemblage of the assembly 100 and therefore achieves a proper fit with the inner surface 40 of the corner bead 38. The configuration of the arch jamb 106 and the second vertical face 132 therefore coincides with the angle and configuration of inner surface 40 of the corner bead 38. Therefore, embodiments of the present invention include this innovative advantage over all of the prior art methods and assemblies 10, which therefore makes the present assembly 100 faster and cheaper to make, easier to install, and more aesthetically pleasing.

According to another inventive aspect of embodiments of the present invention, it is further contemplated that the engagement leg interface 102 of the connective end 128 to the respective vertical jamb member 104 may create a slip joint 146. In particular, the slip joint 146 is created where the first vertical face 130 mates with the internal surface 116 of the vertical jamb member 104. The slip joint 146 is particularly useful in several situations. For example, as mentioned above, if there is unexpected vertical shifting between the horizontal face 134 of the leg interface 102 and the top surface 120 of the vertical jamb member 104 over a distance less than the first interface height 140, the slip joint 146 ensures that no visible gap is created between the connective end 128 and the vertical jamb member 104. In addition, the continuing engagement of the second vertical face 132 with the opposing parallel side 110 of the door frame 108 tends to ensure the continuing structural stability of the assembly 100 during such vertical shifting.

Further, if the connective end 128 requires adjustment during construction, particularly when the connective end 128 needs to be raised with respect to the top surface 120 of the respective vertical jamb member 104, the slip joint 146 allows the connective end 128 to be vertically adjusted without creating a visible gap between the vertical jamb member 104 and the connective end 128. In such circumstances, when a gap needs to be created in order to vertically adjust a connective end 128, an appropriate filler material may be placed intermediate the top surface 120 of the vertical jamb member 104 and the horizontal face 134 of the leg interface 102 in order to ensure the structural integrity of the assembly 100. Preferably, a filler material thus used should have strength properties similar to those of the vertical jamb member 104.

Additionally, it will be appreciated by one of skill in the art that the use of the slip joint 146 ensures that the door jamb arch assembly 100 may be readily adjusted and easily finished with any variety of finishing materials. According to the prior art teachings, the adjustment of the arch jamb 14 in relation to the vertical jamb member 104 may have been impossible as shown in the illustration in FIGS. 1 and 1A. As shown therein, the prior art arch jamb 14 fits within a notch 16 that is cut into an upper end portion 18 of the prior art side jamb 12. In such a configuration, the prior art arch jamb 14 cannot be vertically adjusted with respect to the upper end portion 18 of the prior art side jamb 12 unless the notch 16 is physically altered. In order to accomplish the physical alteration of the notch 16, one may be required to create another notch 16 and fill in the unneeded portion of the previous notch 16. This alteration may be impractical, difficult, nullify the structural contribution of the side jamb 12, and thus require entire replacement of the prior art side jamb 12.

Furthermore, even in prior art embodiments that allow the prior art arch jamb 14 to be vertically adjusted with respect to the upper end portion 18 of the side jamb 12, as shown in FIGS. 2 and 2A, a gap is created therein which must be filled and which also may produce an unsightly seam between the arch jamb 14 and the side jamb 12. In such a case, a customer may be disappointed with the finished product. Over time, with use and wear, the subpar assembly 10 may reveal the gap that exists between the prior art arch jamb 14 and the prior art side jamb 12. In order to produce an excellent product, such drawbacks should be eliminated.

Finally, another prior art arch jamb assembly 10 makes vertical adjustment of the prior art arch jamb 14 possible with respect to the upper end portion 18 of the side jamb 12, as shown in FIGS. 3 and 3A, without leaving a detectable or visible gap or seam therebetween. While this result may prove to be aesthetically sufficient, the prior art assembly 10 illustrated in FIGS. 3 and 3A nevertheless fails to incorporate the structural benefit provided by embodiments of the present invention. Namely, as discussed above, in the event of a relatively downward force upon the prior art arch jamb 14, a resulting horizontal outward force may be produced. In the configuration shown in FIGS. 3 and 3A, the horizontal outward force will only be countered by a lower portion 32 of the prior art arch jamb 14, as explained above. As a result, an extraordinary stress concentration may be created along an internal corner 34 of the distal end of the prior art arch jamb 14. This stress concentration may then cause high local stresses that may result in the splitting or splintering of the prior art arch jamb 14 along its length. Not only will this result compromise the aesthetic qualities of the prior art arch jamb assembly 10, but it will also compromise the structural stability and strength of the prior art arch jamb assembly 10.

As explained above, embodiments of the present door jamb arch assembly 100 ensure that the distribution of loads placed on the arch jamb 106 is even and does not result in unnecessary or premature failure of the assembly 100. As shown in FIGS. 6 and 6A, the engagement of the connective end 128 to the distal end of the vertical jamb member 104 and to the opposing parallel side 110 of the door frame 108 ensures that loads and stresses are evenly distributed within the connective end 128 so as to mitigate against any premature failure of the arch jamb assembly 100. Further, it tends to ensure that the arch jamb assembly 100 may withstand common shifts or adjustments in the construction without producing a visible gap between the connective end 128 and the vertical jamb member 104. For example, as mentioned above, in a situation where a filler material is deposited intermediate the top surface 120 of the vertical jamb member 104 and the horizontal face 134 of the leg interface 102 of the arched jamb member in order to vertically adjust the connective end 128 with respect to the distal end of the vertical jamb member 104, the slip joint 146 allows the arch jamb 106 to be vertically adjusted without leaving an exposed or visible gap intermediate the vertical jamb member 104 and the arch jamb 106. Furthermore, the mating of the second face of the connective end 128 with the respective parallel side 110 of the door frame 108 ensures that any loads or stresses transmitted through the connective end 128 are not born solely at the first vertical face 130 of the connective end 128. Therefore, the stress concentration may be more evenly distributed and not result in a high stress concentration at the intersection 144 of the first vertical face 130 and horizontal face 134 of the leg interface 102.

While the slip joint 146 and the unique mating of the leg interface 102 with the vertical jamb member 104 and the opposing parallel side 110 of the door frame 108 may ensure that the door jamb arch assembly 100 is adjustable and structurally sound during initial construction phases, these same features also provide other unique advantages. For example, in the event of an earthquake, whether large or small, or even during the settling of a building, the building structure often has the tendency to shift. In such situations, as mentioned above, any minor shifting may result in a dramatic change in the loading and stress distribution within the building structure. Thus, in a doorway, which may often be subject to stresses, shifting, and other vibrations, as a result of simple door slams or even small earthquakes, any such shifting (i.e., movement of the arch jamb 106 with respect to the vertical jamb member 104) may be properly withstood due to the innovative configuration of embodiments of the present invention. In particular, such gradual and minimal vertical movement of the connective end 128 of the arch jamb 106 may be undetected by an individual. Referring again to FIGS. 1, 1A, 2, and 2A, any vertical displacement of the prior art arch jamb 14 with respect to the prior art side jamb 12 may result in a detectable gap; however, such vertical displacement may also result in the failure of the assembly 10, as discussed in reference to FIGS. 3 and 3A. Further, the prior art arch jamb 14 of FIGS. 1 and 1A may be dislodged from the notch 16. The prior art arch jamb 14 of FIGS. 2, 2A, 3, and 3A may also be dislodged from the distal top end 24 of the prior art side jamb 12 if the prior art arch jamb 14 is displaced at a great enough distance. In addition, the prior art arch jamb assembly 10 of FIGS. 2 and 2A may also create undesirable results upon vertical displacement of the prior art arch jamb 14 with respect to the prior art vertical jamb member 104. In such a case, a gap would likely develop which would be unsightly. Further, such an unsightly development may require that the prior art door jamb assembly 10 be removed, even if it were structurally sound, because of the questions of structural soundness and appearance that may likely arise. Finally, the prior art arch jamb 14 of FIGS. 3 and 3A may be broken or fractured due to significant horizontal forces. In such a case, the prior art arch jamb 14 of FIGS. 3 and 3A has no feature or structure other than the lower portion 32 thereof to impede the horizontal displacement of the prior art arch jamb 14. Therefore, the prior art arch jamb assemblies 10 of FIGS. 1, 1A, 2, 2A, 3, and 3A fail to provide many of the unique features illustrated in embodiments of the present invention.

Referring now to FIG. 9, it is contemplated that the leg interface 102 of the connective end 128 of the arch jamb 106 may be fabricated utilizing a dado 148 having a dado diameter 150 and a saw blade 152 having a saw blade diameter 154. The dado diameter 150 should be less than the saw blade diameter 154. The dado 148 and the saw blade 152 should be coaxially disposed with respect to each other on a table saw 156. In this regard, the dado 148 defines a dado width 158, which preferably corresponds to the interface width of the horizontal face 134 of the leg interface 102. Further, the difference between the dado diameter 150 and the saw blade diameter 154 should be greater than two times the second interface height 142 of the second vertical face 132.

When being fabricated, the connective end 128 of the arch jamb 106 should be positioned on the table saw 156 and firmly held in place while the dado 148 and saw blade 152 cut and shape the leg interface 102, as shown in FIG. 9 and 10. The leg interface 102, as discussed above, includes the first and second vertical faces 130, 132 and the horizontal face 134. FIG. 10 illustrates the position of the connective end 128 with respect to the table saw 156 during the cutting process, and also shows a cut-out portion 160 of the connective end 128 that is removed during operation of the dado 148 and saw blade 152. In reference to FIG. 9, the dado 148 is utilized to create a rabbet (shown in greater detail in FIG. 10) at the connective end 128 of the arch jamb 106. This rabbet thus creates the horizontal face 134 and the second vertical face 132 of the leg interface 102. Similarly, the first vertical face 130 of the leg interface 102 is formed by the action of the saw blade 152. As shown in FIG. 9, a single pass of the dado 148 and saw blade 152 may thus remove the cut-out portion 160 (shown in FIG. 10) of the connective end 128, which forms the first and second vertical faces 130, 132 and the horizontal face 134.

FIG. 10 shows a partial front view of the connective end 128 illustrating a cut-out portion 160 of the arch jamb 106 that may be removed during the machining process. The removal of the cut-out portion 160 of the connective end 128 provides a proper fitting for the top end 114 of the vertical jamb member 104. As mentioned, the illustration in FIG. 10 provides an exemplary configuration for the connective end 128, but may be fabricated in a variety of shapes to aid in constructing the assembly 100. Features such as slots, grooves, or other structural cut-outs or inserts may be used to enhance the alignment, strength, or other properties of the leg interface 102.

Referring again to FIGS. 9 and 10, in order to properly align the connective end 128 of the arch jamb 106 with the dado 148 and saw blade 152, the arch jamb 106 should be placed on the table saw 156 such that only the connective ends 128 of the arch jamb 106 are touching the table saw 156. In this regard, a fence 162 should be used to ensure that the distal end of the arch jamb 106 passes over the dado 148 and saw blade 152 to form a cut that is preferably parallel to a central axis 164 of the arch jamb 106, although some configurations of the door frame 108 may require otherwise. The use of the fence 162 and a guide fixture 166 will tend to ensure that the cut is evenly made. One should exercise caution to ensure that the dado 148 and saw blade 152 do not throw the arch jamb 106, which may be possible during the cutting process. Other modifications may also be utilized to ensure that the arch jamb 106 is not thrown and also that the cuts are made properly and as required. It is contemplated that one of skill in the art may devise alternative configurations to ensure that the cuts are parallel to the central axis 164 of the arch jamb 106. Thus, if both of the leg interfaces 102 of the arch jamb 106 are cut parallel to each other, this will ensure that the arch jamb 106 may be properly seated on the opposing vertical jamb members 104.

It should be noted that the fabrication of embodiments of the present invention allow for a simpler fabrication of the door jamb arch assembly 100 when compared to other prior art arch jamb assemblies 10, particularly those shown in FIGS. 1, 1A, 2, and 2A. Specifically, the vertical jamb members 104 do not need to be altered as long as the top surfaces 120 thereof are perpendicular to the internal and external surfaces 116, 118 thereof (the distal ends being shaped as horizontal parallelepipeds). Therefore, unlike the prior art assemblies 10 which required the side jambs 12 to have distinct cuts at specified ends thereof (see FIGS. 1 and 2), the vertical jamb members 104 may be reversible without any consequence. Thus, there are no “tops” or “bottoms” to the vertical jamb member 104, which makes assembly much easier and problem-free. In contrast, the prior art methods shown in FIGS. 1, 1A, 2, and 2A require that not only the prior art arch jamb 14 be machined, but also that the prior art side jambs 12 be machined as well. Thus, it is contemplated that embodiments of the present invention may be easily fabricated and provide greater advantages than prior art arch jamb assemblies 10.

It is also contemplated that the connective ends 128 of the arch jamb 106 may be fastened to the vertical jamb members 104. Such fastening may be accomplished by use of fasteners 168 such as adhesives, staples, or screws. Such fasteners 168 may thus contribute to the structural stability and strength of the doorjamb arch assembly 100.

The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of installing, cutting, or otherwise adapting the door jamb arch assembly 100. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.

Claims

1. A door jamb arch assembly for obtaining improved structural support in a door frame, the door frame including opposing parallel sides and a horizontal support, the opposing parallel sides defining top ends, the horizontal support being interposed between the opposing parallel sides at the top ends thereof, the assembly comprising:

a pair of opposing vertical jamb members each including internal and external surfaces and a top surface at distal ends thereof, the external surfaces thereof abutting the opposing parallel sides of the door frame, the vertical jamb members each further defining a jamb width and a jamb depth; and

an arch jamb interposed between the opposing vertical jamb members, the arch jamb defining a curvature, opposing connective ends, and an upper surface, the connective ends each including a leg interface, the leg interface defining first and second vertical faces and a horizontal face interposed therebetween, the first vertical face of the leg interface being configured to mate with the interior surface of the respective vertical jamb member, the horizontal face of the leg interface being configured to mate with the top surface of the respective vertical jamb member, the second vertical face of the leg interface being configured to engage the respective opposing parallel side of the door frame.

2. The door jamb arch assembly of claim 1, wherein the opposing parallel sides are comprised of 2″×4″ wood studs.

3. The door jamb arch assembly of claim 1, wherein the horizontal support is comprised of a 2″×4″ wood stud.

4. The door jamb arch assembly of claim 1, further comprising a pair of fasteners, wherein each fastener connects a respective one of the connective ends of the arch jamb to a respective one of the vertical jamb members.

5. The door jamb arch assembly of claim 4, wherein the pair of fasteners are screws.

6. The door jamb arch assembly of claim 1, further comprising a corner bead coupled to the external surface of the vertical jamb members and the upper surface of the arch member.

7. A arch jamb assembly comprising:

a pair of opposing vertical jamb members each including internal and external surfaces and a top surface at distal ends thereof, the vertical jamb members each further defining a jamb width and a jamb depth; and

an arch jamb interposed between the opposing vertical jamb members, the arch jamb defining a curvature, opposing connective ends, and an upper surface, the connective ends each including a leg interface, the leg interface defining first and second vertical faces and a horizontal face interposed therebetween, the first vertical face of the leg interface being configured to mate with the interior surface of the respective vertical jamb member, the horizontal face of the leg interface being configured to mate with the top surface of the respective vertical jamb member.

8. The arch jamb assembly of claim 7, wherein the arch jamb assembly is interposed between opposing parallel sides, wherein the second vertical face of each leg interface is configured to engage a respective one of the opposing parallel sides.

9. The arch jamb assembly of claim 8, wherein the opposing parallel sides are comprised of 2″×4″ wood studs.

10. The arch jamb assembly of claim 7, further comprising a pair of fasteners, wherein each fastener connects a respective one of the connective ends of the arch jamb to a respective one of the vertical jamb members.

11. The arch jamb assembly of claim 10, wherein the pair of fasteners are screws.

12. The arch jamb assembly of claim 7, further comprising a corner bead coupled to the external surface of the vertical jamb members and the upper surface of the arch member.

13. A arch jamb assembly comprising:

a pair of opposing vertical jamb members each including internal and external surfaces and a top surface at distal ends thereof, the vertical jamb members each further defining a jamb width and a jamb depth;

an arch jamb interposed between the opposing vertical jamb members, the arch jamb defining a curvature, opposing connective ends, and an upper surface, the connective ends each including a leg interface, the leg interface defining first and second vertical faces and a horizontal face interposed therebetween, the first vertical face of the leg interface being configured to mate with the interior surface of the respective vertical jamb member, the horizontal face of the leg interface being configured to mate with the top surface of the respective vertical jamb member; and

a pair of fasteners, wherein each fastener connects a respective one of the connective ends of the arch jamb to a respective one of the vertical jamb members.

14. The arch jamb assembly of claim 13, wherein the arch jamb assembly is interposed between opposing parallel sides, wherein the second vertical face of each leg interface is configured to engage a respective one of the opposing parallel sides.

15. The arch jamb assembly of claim 14, wherein the opposing parallel sides are comprised of 2″×4″ wood studs.

16. The arch jamb assembly of claim 13, further comprising a corner bead coupled to the external surface of the vertical jamb members and the upper surface of the arch member.

17. The arch jamb assembly of claim 13, wherein the pair of fasteners are screws.