ADJUSTABLE DOOR FRAME FOR A SLIDING DOOR

Abstract

A door frame for a sliding door system may include three (3) portions having an upper portion disposed adjacent an upper end of a door opening and two side portions disposed along either edge of the door opening. A first frame segment and the second frame segment are adjustable with respect to each other in order to extend around different thickness of different door openings. The first frame segment and/or the second frame segment may have one or more caps, retainers, headers or the like coupled to the frame segments. The caps, retainers, or headers may have portions that are trimmed in order to allow them to mate with portions of the first frame segment or the second frame segment. The adjustment of the segments may be made before or after being installed.

Description

CROSS REFERENCE AND PRIORITY CLAIM UNDER 35 U.S.C. § 119

The present Application for a Patent claims priority to U.S. Provisional Patent Application Ser. No. 63/278,515 entitled “Adjustable Door Frame for a Sliding Door” filed on Nov. 12, 2021, U.S. Provisional Patent Application Ser. No. 63/278,513 entitled “Security Features for a Sliding Door System” filed on Nov. 12, 2021, U.S. Provisional Patent Application Ser. No. 63/276,227 entitled “Adjustable Frame with a Thermal Break Seal” filed on Nov. 5, 2021, U.S. Provisional Patent Application Ser. No. 63/276,230 entitled “Adjustable Frame With a Thermal Break” filed on Nov. 5, 2021, U.S. Provisional Patent Application Ser. No. 63/197,770 entitled “Adjustable Door Frame With a Thermal Break” filed on Jun. 7, 2021, all of which are assigned to the assignees hereof and hereby expressly incorporated by reference herein.

FIELD

Embodiments of the present disclosure generally relate to door frames for sliding door openings, and in particular, to adjustable door frames for assembly of the door frames with walls of different thicknesses.

BACKGROUND

Walls within a building, such as within individual rooms, between rooms, and/or between floors may be of different sizes, and thus, require different door frames.

SUMMARY

As will be described herein, embodiments of the door frame may comprise three (3) portions comprising an upper portion disposed adjacent an upper end of a door opening and two side portions disposed along either edge of the door opening. One side portion is located on one side of the door opening and the opposite side portion is located on the opposite side of the door opening. Each of the door frame portions may be made up of a pair of elongated frame segments of sufficient length to fit the door opening. The frame segments are assembled around the opening edges of wall that form the door opening. A first frame segment may be disposed on the outer side of the door opening (e.g., the side of wall that is normally outside of the door), and second frame segment may be disposed on the inner side of the door opening (e.g., the side of the wall that is normally enclosed by the door). However, in some embodiments the first frame segment may be disposed on the inner side of the door opening and the second frame segment may be disposed on the outer side of the door opening. The frame portions may be secured to each other and the adjoining structure by frame connectors (e.g., clips, tabs, fasteners, and/or the like). A sliding door may be hung conventionally on the inner side or outer side of the door opening using sliding door hardware. The door may be any type of conventional door, any customized door, or the like and made of any material (e.g., wood, metal, plastic, composite, or the like).

The first frame segment and the second frame segment may adjust with respect to each other in order in order to extend around the thickness of the door opening to account for different walls having different thicknesses. The segments may be operatively coupled together through the use of one or more segment connectors (e.g., clips, tabs, fasteners, and/or the like). Moreover, the first frame segment and/or the second frame segment may have one or more caps, a receiver, a header, or the like. The one or more caps (e.g., facia, covers, or the like) may cover at least a portion of the first frame segment and/or the second frame segment and/or the segment connectors that operatively couple the frame segments together. The receiver may be used to receive an edge of the sliding door. The header member may be used to receive a top edge of the of the sliding door and/or to conceal the sliding door hardware.

One embodiment of the invention comprises an adjustable door frame for a sliding door. The adjustable door frame comprising a first frame segment having a first molding flange and a first jamb flange, and a second frame segment having a second molding flange and a second jamb flange. The first frame segment is adjustable with respect to the second frame segment, and at least a portion of the first jamb flange and at least a portion of the second jamb flange overlap.

In further accord with embodiments, an outer surface of the first jamb flange and an outer surface of the second jamb flange are planer.

In other embodiments, the door frame further comprises one or more segment connectors extending through the first molding flange, the second molding flange, the first jamb flange, or the second jamb flange and into a portion of a support member.

In yet other embodiments, the door frame comprises a first molding cap having one or more first cap projections. The first molding flange comprises one or more first molding projections. The one or more first cap projections and the one or more first molding projections operatively coupled the first molding cap to the first molding flange.

In still other embodiments, the first molding cap comprises a molding cap face and a jamb cap leg operatively coupled to the molding cap face. An outer surface of the jamb cap leg is flush with an outer surface of the first jamb flange.

In other embodiments, the door frame further comprises a second molding cap having one or more second cap projections. The second molding flange comprises one or more second molding projections. The one or more second cap projections and the one or more second molding projections operatively couple the second molding cap to the second molding flange.

In further accord with embodiments, the second molding cap comprises a molding cap face and a jamb cap leg operatively coupled to the molding cap face. A portion of the jamb cap leg overlaps a portion of the second jamb flange.

In other embodiments, the first jamb flange overlaps a portion of the second jamb flange. An end of the jamb cap leg is adjacent and end of the first jamb flange and an outer surface of the first jamb flange and an outer surface of the jamb cap leg are flush.

In yet other embodiments, the door frame further comprises a first molding cap operatively coupled to the first molding flange. The first molding cap comprises a first molding cap face and a first jamb cap leg operatively coupled to the first molding cap face. A portion of the first jamb cap leg overlaps at least a portion of the first jamb flange. The door frame further comprises a second molding cap operatively coupled to the second molding flange. The second molding cap comprises a second molding cap face, and a second jamb cap leg operatively coupled to the second molding cap face. An outer surface of the second jamb cap leg and the outer surface of the first jamb cap leg are flush.

In still other embodiments, the first jamb cap leg overlaps the first jamb flange and the second jamb flange, and wherein an end of the first jamb cap leg is adjacent an end of the second jamb cap leg.

In other embodiments, the second jamb cap leg overlaps at least a portion of the second jamb flange, and wherein an end of the second jamb cap leg is adjacent an end of the first jam cap leg.

In further accord with embodiments, the first jamb flange or the second jamb flange are operatively coupled to each other or a support member using one or more segment connectors; and wherein the first jamb cap leg or the second jamb cap leg conceal the one or more segment connectors.

In other embodiments, the first frame segment comprises one or more proximal jamb portions, and one or more distal jamb portions operatively coupled to the one or more proximal jamb portions. The one or more proximal jamb portions adjacent the one or more distal jamb portions form one or more jamb channels that receive at least a portion of the second jamb flange.

In still other embodiments, the door frame further comprises a receiver. The receiver comprises a receiver mount having one or more mount projections, and one or more walls forming a receiver channel. The first molding flange comprises one or more molding projections. The one or more mount projections and the one or more molding projections operatively couple the receiver to the first molding flange. The receiver channel receives a side of a door.

In yet other embodiments, the door frame further comprises a header. The header comprises a header mount, a header body operatively coupled to the header mount, and a header cap operatively coupled to the header mount or the header body. The header mount, the header body, or the header cap form a header channel. The header channel receives upper portion of the door.

Another embodiment of the invention comprises a door system. The door system comprises an adjustable door frame comprising a first frame segment having a first molding flange and a first jamb flange, and a second frame segment having a second molding flange and a second jamb flange. The first frame segment is adjustable with respect to the second frame segment and at least a portion of the first jamb flange and at least a portion of the second jamb flange overlap. The adjustable door frame is operatively coupled to edges of a door opening. The door system further comprises sliding door hardware operatively coupled to a wall or the adjustable door frame, and a door operatively coupled to the sliding door hardware.

In further accord with embodiments of the invention, an outer surface of the first jamb flange and an outer surface of the second jamb flange are planer.

In other embodiments, the door system further comprises one or more segment connectors extending through the first molding flange, the second molding flange, the first jamb flange, or the second jamb flange and into a portion of a support member.

In still other embodiments, the door system further comprises a first molding cap having one or more first cap projections. The first molding flange comprises one or more first molding projections. The one or more first cap projections and the one or more first molding projections operatively coupled the first molding cap to the first molding flange.

Another embodiment of the invention comprises a method of forming a door frame. The method comprises adjusting a first frame segment with respect to a second frame segment based on a width of a wall at a door opening. The first frame segment comprises a first molding flange and a first jamb flange and the second frame segment comprises a second molding flange and a second jamb flange. At least a portion of the first jamb flange and at least a portion of the second jamb flange overlap. The method further comprises securing the first frame segment and the second frame segment to the wall at the door opening.

To the accomplishment the foregoing and the related ends, the one or more embodiments comprise the features hereinafter described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described embodiments of the invention in general terms, reference will now be made to the accompanying drawings.

FIG. 1A is front perspective view of one side of the sliding door system, in accordance with some embodiments of the present disclosure.

FIG. 1B is a front exploded perspective view of one side of the sliding door system, in accordance with some embodiments of the present disclosure.

FIG. 2 is a perspective view of a portion of the adjustable door frame, in accordance with some embodiments of the present disclosure.

FIG. 3A illustrates a cross-sectional view of the adjustable door frame installed to metal studs, in accordance with some embodiments of the present disclosure.

FIG. 3B illustrates a cross-sectional view of the adjustable door frame installed to a masonry wall, in accordance with some embodiments of the present disclosure.

FIG. 3C illustrates a cross-sectional view of the adjustable door frame installed to wood studs, in accordance with some embodiments of the present disclosure.

FIG. 4 illustrates a cross-sectional view of the adjustable door frame having caps, in accordance with some embodiments of the present disclosure.

FIG. 5 illustrates a cross-sectional view of the adjustable door frame having caps that are flush with the door frame segments, in accordance with some embodiments of the present disclosure.

FIG. 6 illustrates a cross-sectional view of the adjustable door frame having caps that cover the segment connectors, in accordance with some embodiments of the present disclosure.

FIG. 7 illustrates a cross-sectional view of the adjustable door frame having a receiver, in accordance with some embodiments of the present disclosure.

FIG. 8 illustrates a cross-sectional view of the adjustable door frame having a header, in accordance with some embodiments of the present disclosure.

FIG. 9 illustrates cross-sectional views different header caps, in accordance with some embodiments of the present disclosure.

FIG. 10 illustrates a cross-sectional view of the adjustable door frame having an one or more segment channels, in accordance with some embodiments of the present disclosure.

FIG. 11A illustrates a cross-sectional view of the adjustable door frame having the one or more segment channels, in accordance with some embodiments of the present disclosure.

FIG. 11B illustrates a cross-sectional view of the adjustable door frame having the one or more segment channels, in accordance with some embodiments of the present disclosure.

FIG. 12A illustrates a cross-sectional view of the adjustable door frame having the one or more segment channels and cap with a seal, in accordance with some embodiments of the present disclosure.

FIG. 12B illustrates a cross-sectional view of the cap with a seal channel, in accordance with some embodiments of the present disclosure.

FIG. 13A is a perspective view of a portion of the door frame, in accordance with some embodiments of the disclosure.

FIG. 13B is a bottom perspective view of a portion of the door frame, in accordance with some embodiments of the disclosure.

FIG. 14 illustrates a process for installing the adjustable door frame for a sliding door, in accordance with some embodiments of the disclosure.

DETAILED DESCRIPTION

The following detailed description teaches specific example embodiments of the invention; however, other embodiments of the invention do not depart from the scope of the present invention. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Like reference numbers reference to like elements.

The present disclosure relates to apparatuses, systems, and/or methods for an adjustable frame 20 for a wall 2 around the surfaces 8 of a door opening for a sliding door system 1 having a sliding door 10. A sliding door system 1 may comprise one or more sliding doors 10 and sliding door hardware 4 (e.g., a track system, including tracks, wheels, supports, stops, seals, and/or the like, a soft close apparatus, including one or more actuators —not illustrated, and/or the like) operatively coupled to the door 10, wall 2, door frame 20, or one or more door opening surfaces 8 that surround and/or are located within the opening of door). It should be understood that the sliding door 10 may be any type of sliding door 10, such as but not limited to a single sliding door, bypass doors, pocket sliding doors, patio sliding doors, barn sliding doors, bi-part sliding doors, or any other type of sliding door. As such, it should be understood that when discussing “a sliding door” herein, this may refer to any type of sliding door, and/or one or more sliding doors (e.g., such as bi-part sliding doors, or the like). Regardless of the type of door 10, the door 10 may have edges 11, such as opposing edges 12, 13 a top edge 15, a bottom edge 16, and opposing faces 17, such as a first face 18 (e.g., a front face) and a second face 19 (e.g., a back face). In some embodiments the one or more sliding doors 10 may be hollow, solid, sound rated, projectile resistant (e.g., weather resistant, ballistic resistant, blast resistant, or the like), fire rated, electromagnetic (EMI-RFI) shielded door, or the like, and as such, the sliding doors may include a specialized core.

Embodiments of the invention will be described with respect to FIGS. 1A through 12B illustrating a door frame 20 (e.g., otherwise described as an adjustable door frame, an adjustable sliding door frame, or the like) and/or components thereof. As illustrated in FIGS. 1A and 1B, the door frame 20 may comprise three (3) portions including an upper portion 24 disposed adjacent an upper end of a door opening, and two side portions 26, 28 disposed along either edge of the door opening. Each portion 24, 26, 28 may be made up of two or more elongated frame segments (e.g., a pair of elongated frame segments 30, 40) of sufficient length to fit the door opening. The frame segments 30, 40 are assembled around the open edges 8 of wall 2. A first frame segment 30 may be disposed on the outer side of the door opening (e.g., the side of wall that is normally outside of the door), and a second frame segment 40 may be disposed on the inner side of the door opening (e.g., the side of the wall that is normally enclosed by the door). However, in some embodiments the first frame segment 30 may be disposed on the inner side of the door opening and the second frame segment 40 may be disposed on the outer side of the door opening. In other embodiments, additional door frame segments may be utilized. The door frame portions 24, 26, 28 may be secured to each other and/or an adjoining structure by frame connectors 22 (e.g., clips, tabs, fasteners, or the like). As further illustrated in FIG. 1A, a door 10 may be hung otherwise conventionally on the wall through sliding door hardware 4, which will be described in further detail herein. The door 10 may be any type of conventional door, any customized door, or the like.

As illustrated in FIGS. 2 through 8, each portion of the adjustable door frame 20 may comprise as first frame segment 30 having a first molding flange 32 that may form a door opening molding (e.g., outer or inner door opening molding), which may be parallel to a wall 2 (e.g., inner or outer wall). Moreover, a first jamb flange 34 extends adjacent to an end of the first molding flange 32 (e.g., perpendicular to the first molding flange 32, or the like). In some embodiments, the first molding flange 32 and the first jamb flange 34 may be an L-shaped member. In some embodiments, the first jamb flange 34 may have a planer surface. The second frame segment 40 may have a second molding flange 42, which may be parallel to a wall 2 (e.g., inner or outer wall). Moreover, a second jamb flange 44 may extend adjacent to an end of the second molding flange 42 (e.g., perpendicular to the second molding flange 42, or the like). In some embodiments, the second molding flange 42 and the second jamb flange 44 may be an L-shaped member. In some embodiments, the second jamb flange 44 may have a planer surface.

The first frame segment 30 and the second frame segment may be positioned around the internal edges 8 of the door opening. As illustrated in FIGS. 3A through 3C, the first frame segment 30 and the second frame segment 40 may be adjustable to account for different wall sizes, which may vary based on the width of the support members (e.g., studs, masonry, or the like), wall material thicknesses (e.g., drywall, plaster, sheet metal, or the like), or other like factors. As such, the adjustable door frame 20 may be installed on any wall having different thicknesses, that is, specific door frames 20 do not have to be ordered for each door opening. In some embodiments, the adjustable door frame 20 may provide for an adjustment range of 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5., 6.5, 7, or the like inches of adjustment between the first frame segment 30 and the second frame segment 40. Also, it should be understood that only one set of segments 30, 40 are needed to provide adjustment; however, in some embodiments the first frame segment 30 and/or second frame segment 30 may be swapped out with different segments (e.g., of different sizes, such as different lengths of the jamb flanges 34, 44) to provide larger or smaller ranges of adjustments.

As illustrated in FIG. 3A, the adjustable door frame 20 may be utilized on walls formed from steel studs and drywall. Alternatively, FIG. 3B illustrates that the adjustable door frame 20 may be used on masonry walls. Furthermore, as illustrated in FIG. 3C, the adjustable door frame 20 may be used on walls that have wood studs and drywall. Regardless of the type of wall, the first segment 30 may at least partially overlap at least a portion of the second segment 40. For example, at least a portion of the first jamb flange 34 may overlap at least a portion of the second jamb flange 44, as illustrated in FIGS. 3A-3C. However, in alternate embodiments, at least a portion of the second jamb flange 44 may overlap at least a portion of the first jamb flange 34. In still alternate embodiments, the first jamb flange 32 and/or the second jamb flange 34 may be trimmed in order to change the range of adjustment and/or to allow the ends of the first jamb flange 34 and/or second jamb flange 44 to butt into each other (not illustrated) instead of overlapping.

The adjustable door frame 20 may be operatively coupled to the wall (e.g., the support member thereof, or the like) through the use of one or more segment connectors 150 (e.g., clips, tabs, fasteners, welds, and/or the like), such as first segment connectors 152, 154 and/or second segment connectors 156, 158. As illustrated in FIGS. 3B and 3C, some first segment connectors 152 may extend through the first molding flange 32 and into the wall 2 (e.g., drywall, support member, masonry, or the like) and/or some first segment connectors 154 may extend through the first jamb flange 34 and into the door opening edge (e.g., the support member, or the like). As further illustrated in FIGS. 3B and 3C, some second segment connectors 156 may extend through the second molding flange 42 and into the wall 2 (e.g., drywall, support member, masonry, or the like) and/or some second segment connectors 158 may extend through the first jamb flange 44 and into the door opening edge (e.g., the support member, or the like). It should be understood that the first segment connectors 154 and the second segment connectors 158 may be the same segment connector 150 (e.g., extending through both the first jamb flange 34 and the second jamb flange 36).

As illustrated in FIG. 4, in some embodiments one or more caps may be utilized to cover at least a portion of the first segment 30 and/or the second segment 40. For example, the first segment 30 may comprise a first molding cap 60 having a molding cap face 64 (e.g., parallel with the wall 2) and two molding cap legs 62, 66 (e.g., perpendicular with the wall 2), such as a wall molding cap leg 62 (e.g., adjacent the wall) and a jamb molding cap leg 66. The jamb molding cap leg 66 may be flush with the outer surface of the first jamb flange 34. Additionally, the second segment 30 may comprise a second molding cap 60 having a molding cap face 74 (e.g., parallel with the wall 2) and two molding cap legs 72, 76 (e.g., perpendicular with the wall 2), such as a wall molding cap leg 72 (e.g., adjacent the wall) and a jamb molding cap leg 76. The jamb molding cap leg 76 may be flush with the outer surface of the first jamb flange 44.

The first molding cap 60 and the second molding cap 70 may have one or more cap projections (e.g., a proximal cap projection 82, a distal cap projection 84, or the like) that interact with one or more flange projections (e.g., a proximal flange projection 52 and a distal flange projection 54). The molding caps 60, 70 may be operatively coupled to first flange segment 30 and the second flange segment 40, respectively, through the one or more cap projections being operatively coupled to the one or more flange projections. For example, the proximal cap projections 82 may be operatively coupled to the proximal flange projections 52 and/or the distal cap projections 84 may be operatively coupled to the distal flange projections 54 (e.g., snap fit together—over or between each other, or the like). However, it should be understood that the first molding cap 60 and the second molding cap 70 may be operatively coupled to the first flange segment 30 and the second flange segment 40 in other ways.

FIG. 5 illustrates that in some embodiments a portion of cap may extend over a jamb flange and/or butt against a jamb flange. For example, the jamb molding cap leg 76 may extend over the second jamb flange 44 of the second frame segment 40. In some embodiments, the inner surface of the jamb molding cap leg 76 may contact the outer surface of the second jamb flange 44. Furthermore, in some embodiments, the end of the jamb molding cap leg 76 may butt up to the end of the first jamb flange 34. As such, in some embodiments as illustrated in FIG. 5, the outer surface of the second jamb molding cap leg 76, the outer surface of the first jamb flange 34, and the outer surface of the first jamb molding cap leg 66 may be flush and in the same plane.

It should be understood that should the second jamb flange 44 of the second frame segment 40 overlap the first jamb flange 34 of the first frame segment 30, then the first molding cap 60 may have the configuration of the second molding cap 70 described above. That is, the first jamb molding cap leg 66 may extend over the first jamb flange 34 of the first frame segment 40. In some embodiments, the inner surface of the first jamb molding cap leg 66 may contact the outer surface of the first jamb flange 34. Furthermore, in some embodiments, the end of the first jamb molding cap leg 66 may butt up to the end of the second jamb flange 44. As such, in some embodiments the outer surface of the first jamb molding cap leg 66, the outer surface of the second jamb flange 44, and the outer surface of the second jamb molding cap leg 76 may be flush and in the same plane.

As will be described in further detail herein, the jamb molding cap legs 66, 76 may be trimmed on site as needed depending on the thickness of the wall. For example, the thickness of the wall will set the location of the end of the first jamb flange 34 and the second jamb flange 44. Consequently, one or more of the jamb molding cap legs 66, 76 may be trimmed to butt up to the end of the first jamb flange 34 or the second jamb flange 44, respectively.

FIG. 6 further illustrates in some embodiments at least a portion of a cap (e.g., illustrated as the first segment cap 60 may extend over one or more jamb flanges 34, 44, cover one or more segment connectors 150, be operatively couple to a portion of the jamb flanges (e.g., illustrated as a projection on the second jamb flange 44) and/or an opposing cap (e.g., illustrated as the second segment cap 70). For example, as illustrated in FIG. 6, a first jamb molding cap leg 66 may be offset from (e.g., spaced apart from, or the like) and/or extend over the first jamb flange 34. As further illustrated in FIG. 6, the first jamb molding cap leg 66 may extend over at least a portion of the second jamb flange 44. In the illustrated embodiment, the first jamb molding cap leg 66 may have a leg projection 67 that is operatively coupled with a flange projection 45 of the second jamb flange 44. However, in order to allow for the adjustability of the first frame segment 30 and the second frame segment 40, there may be one or more leg projections 67 and one more flange projections 45 that can be trimmed and used depending on the adjustment made between the first frame segment 30 and the second frame segment. Alternatively, one or more leg projections 67 and one or more flange projections 45 may not interact with each other, but act only as a stand-off and/or support for the first jamb molding cap leg 66. In other embodiments the end of the first jamb molding cap leg 66 may be operatively coupled a portion of the second molding cap 70 (e.g., the molding cap face 74, the second jamb molding cap leg 76, or the like).

FIG. 7 illustrates that in some embodiments, a retainer 90 may be utilized with the adjustable door frame 20. The retainer 90 may have multiple walls such as a jamb retainer leg 91, a wall retainer leg 92, a retainer face 94, a retainer stop 96, and a retainer mount 98. In some embodiments, the wall retainer leg 92 may also act as the retainer stop 96; however, in the illustrated embodiment, the wall retainer leg 92 and the retainer stop 96 are different walls (e.g., parallel with each other, or the like). The wall retainer leg 92 or the retainer stop 96, the retainer face 94 and the retainer mount 98 form a retainer cavity 99 which receives an edge 12 of the door 10 when the door 10 is in the closed position. The jamb retainer leg 91 may sit flush with the outer face of the first jamb flange 34. However, in other embodiments the jamb retainer leg 91 may extend over the jamb flange 34 and/or the second jamb flange 44 and/or butt against a jamb flange (e.g., second jamb flange 44), as previously described with respect to FIGS. 5 and/or 6. It should be understood that the retainer 90 is illustrated as being used with the first frame segment 30, however, in some embodiments the retainer 90 may be used with the second frame segment 40.

FIG. 8 illustrates a header 100 comprising a header mount 102, a header body 104 (e.g., including hardware 4 for the sliding door, such as tracks, rollers, wheels, dampers, closers, stops, or the like or the like), and a header cap 106. The header 100 may be operatively coupled to the wall 2 over the door frame 20 (e.g., a second frame segment 40 and a second molding cap 70, as illustrated in FIG. 7, or the first frame segment 30 and a first molding cap 60). Alternatively, the header 100 may be operatively coupled to the door frame (e.g., as previously described with respect to the caps). The header 100 may be used to receive the top edge 15 of the door and/or to conceal the door hardware 4 (e.g., tracks, rollers, used for the sliding door system 1. As illustrated in FIG. 9, the header caps 106 for the header 100 may have different configurations (e.g., flat, rounded, angled, or the like).

FIGS. 10 through 12B illustrate other embodiments of the inventions in which at least a portion of the first jamb flange 34 may have one or more proximal jamb portions 36 and one or more distal jamb portions 38 that form one or more first jamb channels 39. FIG. 10 illustrates that each door frame portion may have three first jamb channels 39; however, it should be understood that the majority of, or the entire length of, the door frame portion (e.g., the upper portion 24 disposed adjacent an upper end of a door opening, and two side portions 26, 28 disposed along either edge of the door opening) may have a jamb channel 39. As illustrated in FIGS. 11A and 11B, the one or more first jamb channels 39 may be configured to receive at least a portion of the second jamb flange 44 in order to aid in the first segment 30 and the second segment 40 being adjustable (e.g., slide, or the like) with respect to each other. Alternatively, or additionally, it should be understood that the second jamb flange 44 may have the one or more proximal jamb portions and one or more distal jamb portions that form one or more second jamb channels, which may receive a portion of the first jamb flange 34. As previously discussed herein the one or more segment connectors 150 may be used to operatively couple the first frame segment 30 and the second frame segment 40; however, it should be understood that the jamb channel 39 may not require segment connectors 150 (as illustrated in FIG. 11A), and one or more segment connectors 150 may only be used through the first molding flange 32 and the second molding flange 42.

FIGS. 12A and 12B illustrates, as previously described with respect to FIGS. 4 through 6, one or more caps (e.g., a first segment cap 60, a second segment cap 70, or the like) may be used with the door frame 20 having the one or more jamb channels 39. As illustrated in FIGS. 12A and 12, the one or more caps 60, 70 may have jamb molding cap legs 66, 76, one of which extends over at least one jamb flange (e.g., illustrated as the second jamb flange 42) and butts into the opposite jamb flange (e.g., illustrated as the end of the distal portion 38 of the first jamb flange 32). The one or more caps may be operatively coupled to the first frame segment 30 and the second frame segment 40, as previously described herein (e.g., using one or more projections, or the like). FIG. 12A further illustrates that in some embodiments, the one or more caps may have walls that form a seal channel 172 (e.g., kerf seal channel, or the like) that receives a seal 170 (e.g., kerf seal, or the like), for providing privacy, sound abatement, electromagnetic interference (EMI) shielding, resisting air flow, or the like.

As generally discussed above, the jamb molding cap legs 66, 76 may be long enough to allow for the adjustability of the first frame segment 30 and the second frame segment to be adjusted with respect to each other. After the first frame segment 30 and the second frame segment 40 spacing is determined to fit around the internal surfaces 8 of the door opening. The one or more caps 60, 70 may be trimmed such that the jamb molding cap leg butts into and adjacent jamb flange. As illustrated in FIGS. 12A and 12B, the second segment cap 70 may be trimmed along the second jamb molding cap leg 76 at a trim location 78 and the excess leg portion 79 may be discarded or used for a different purpose. As such, as illustrated the second jamb molding cap leg 76 may butt (e.g., located adjacent to, touch, or the like) up to the end of the first jamb flange 34, such as the distal jamb flange portion 38. While the second segment cap 70 is illustrated as having the jamb molding cap leg 76 that can be trimmed and/or having the seal channel 172 for the seal 170, it should be understood that the first segment cap 60 may have these features.

FIGS. 13A and 13B illustrate alternate ways in which the first frame segment 30 may be operatively coupled to the second frame segment 40. For example, the first frame segment 30 and/or the second frame segment may have an adjustment system 440. In some embodiments, the adjustment system 440 may comprise one or more adjustment members 441. For example, as illustrated in FIG. 13A, the one or more adjustment members 441 (e.g., an adjustment tab, or the like) may be operatively coupled to the second frame segment 40, such as a first adjustment member 446, second adjustment member 448, additional adjustment members, or the like. The one or more adjustment members 44 may be utilized for operative coupling with the first frame segment 30. It should be understood that while the one or more adjustment members 441 may be illustrated as extending from the second frame segment 40, the one or more adjustment members 441 may additionally, or alternatively, extend from the first frame segment 30. The one or more adjustment members 441 may be tabs that extend from one or more jamb flanges 34, 44 (e.g., first jamb flange 34 or second jamb flange 44). Alternatively, or additionally, the one or more adjustment members 441 may be formed separately from, and later operatively coupled to, one or more of the jamb flanges 34, 44.

As illustrated in FIG. 13A, the one or more adjustment members 441 may comprise adjustment tabs 446, 448 having a tab apertures 449 therethrough (e.g., a slotted aperture, or the like). As previously discussed herein, one or more segment connectors 150 may be used in order to facilitate assembly of the one or more adjustment members 444. For example, fasteners, such as anchor screws or locking screws, may be pre-assembled to the first frame segment 30 and/or the second frame segment 40. In some embodiments, pre-formed apertures may be formed in the first frame segment 30 and/or the second frame segment 40. As such, the first frame segment 30 and/or the second frame segment 40 may be shipped disassembled and/or at least partially pre-assembled. For example, as illustrated in FIG. 13A, a fasteners may be assembled through pre-drilled apertures in the first frame segment 30 and through the tab apertures 449 of the adjustment tabs 446, 448 in order to allow the fasteners to slide within the adjustment tabs. When the width of the adjustable frame is set, another fastener may be used to prevent further movement between the first frame segment 30 and the second frame segment.

As illustrated in FIG. 13B, in some embodiments, the adjustment system 440 may comprise the one or more adjustments members 441 previously discussed herein. As such, the one or more adjustment members 441 may comprise a first adjustment member 442 that may be operatively coupled to a second adjustment member 444. The first adjustment member 442 may comprise an adjustment tab 446 having a tab aperture 449 therethrough (e.g., a slotted aperture, or the like). The second adjustment member 444 may comprise an adjustment receptacle 450 (e.g., bracket, or the like) that may receive the adjustment tab 446. The adjustment receptacle 450 may have one or more receptacle flanges 462 that are operatively coupled to the first segment 30 (e.g., welded to the inside surface of the first jamb flange 32, or the like) and one or more receptacle hoods 464 that are offset from the one or more receptacle flanges. The flanges 462 and hood 464 form a receptacle cavity 466 that is configured to receive the adjustment tab 446, such as slidably receive the adjustment tab 446 to allow for a width adjustment of the door frame 20 (e.g., changing the position of the first segment 30 with respect to the second segment 40). The adjustment system 440 may further aid in restricting rotational movement of the first segment 30 with respect to the second segment 40 (e.g., due to the receipt of the adjustment tab 446 within the adjustment receptacle 450). It should be understood that the adjustment receptacle 450 may be factory installed and/or installed in the field (e.g., molding, forming, bonding, welding, or the like).

In order to facilitate the assembly of the one or more adjustment members 441 (e.g., assembly of the first adjustment member 442 to the second adjustment member 444), as illustrated in FIG. 13B, the first segment 30 may have one or more access apertures that allow a user to use one or more of the segment connectors 70 (e.g., a width adjustment connector 72) to operatively couple the first segment 30 to the second segment 40. As illustrated in the figures, one or more segment connectors 70 may be used to operatively couple the first segment 30 to the second segment 40 for preventing further adjustment of the width of the door frame 20. For example, one or more segment connectors 70 may be utilized (e.g., inserted through, accessed if the connectors 70 are self-contained, or the like) through one or more access apertures in the first segment 30 to operatively couple the first adjustment member 442 (e.g., the adjustment tab 446) to the second adjustment member 444 (e.g., the receptacle hood 464 of the adjustment receptacle 450). As illustrated in FIG. 13B, since the first segment 30 can be operatively coupled to the second segment 40 from the outside of the door frame 20, then the door frame 20 may be assembled to a wall of the door opening without having to first set the width of the adjustable door frame 20.

FIG. 14 illustrates a process for manufacturing and/or installing the adjustable door frame 20, as described herein. In some embodiments of the invention, one or more of the door frame segments 30, 40 may be a standard size and configuration. For example, the first door frame segment 30, the second door frame segment 40, or both may be standard sizes. The frame segments 30, 40 may allow for different ranges of thicknesses for different wall thicknesses. Therefore, as illustrated by block 210 of FIG. 14, the segments for the door frame 20 may be manufactured (e.g., rolled, stamped, bent, extruded, molded, or the like). As further illustrated in block 220 of FIG. 14, the one or more caps 60, 70, retainers 90, headers 100 or the like may be manufactured (e.g., rolled, stamped, bent, extruded, molded, or the like). The segments 30, 40, caps 60, 70, retainers 90, headers 100, or the like may be determined, manufactured, and/or provided based on customer preferences.

As such, as illustrated in block 230, in response to receiving an order from a customer, one or more door frames 20 may be shipped to a customer. It should be understood that the segments 30, 40, caps 60, 70, retainers 90, headers 100, or the like may be packaged and shipped unassembled, partially assembly, and/or assembled (e.g., segments, caps, retainer, header, or the like separate or at least partially assembled). Since the segments 30, 40 are adjustable, even though the customer may have walls of different thicknesses, all the segments 30, 40 may be the same size. In alternate embodiments, there may be different size segments 30, 40 that allow for adjust over different ranges of wall thicknesses.

Block 240 further illustrates that on site the installer may assemble the segments 30, 40, and/or a portion of the segments 30, 40, such as operatively coupling the segments 30, 40, together and/or adjusting the segments 30, 40 with respect to each other based on the specific wall thickness of the door opening. As such, the installer may use segment connectors 150 before assembling the door frame portions 24, 26, 28 to the door opening. For example, the first frame segment 30 may be moved with respect to the second frame segment 40 in order to set a frame width for the door frame 20.

Block 250 of FIG. 14 illustrates that the frame portion (e.g., the upper portion 24 disposed adjacent an upper end of a door opening, and two side portions 26, 28 disposed along either edge of the door opening) are installed onto the wall 2 of the door opening. Alternatively, the first frame segment 30 or the second frame segment 40 (e.g., the segment that is overlapped is installed first, or the like) may be installed individually to the wall of the door opening. Regardless of the installation order, the door frame portions 24, 26, 28 may be installed on the upper and side portions of the door opening using frame connectors 25 (e.g., clips, tabs, fasteners, or the like). For example, corner tabs and hanger tabs may be used to secure to the door frame portions 24, 26, 28 to the wall 14 around the door opening and/or to the adjacent door frame portions 24, 26, 28.

Block 260 of FIG. 14 illustrates that insulation or other materials may be applied within one or more cavities of the door frame 20. The insulation may provide thermal protection between the inner side and outer side of the door frame. Alternatively, forced entry (FE) and/or ballistic resistant (BR) material may be provided within the door frame 20 before and/or after assembly within the door opening. In still other embodiments EMI shielding material may be applied to the frame 20 (e.g., outer or inner surfaces of the door frame). Moreover, sealant may be applied (e.g., caulk, adhesive tape, foam, or the like) may be applied to the door frame 20 to join surfaces, hide edges, provide security features, or the like.

FIG. 14 further illustrates in block 270, that the caps 60, 70, retainer 90, and/or header 100 (e.g. including the tracks, wheels, dampers, closers, stops, or the like) are installed to the first frame segment 30, second frame segment 40, wall 2, or the like and/or the door hardware (e.g., tracks, rollers, wheels, dampers, closers, stops, or the like) are assembled to the door 10.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Certain terminology is used herein for convenience only and is not to be taken as a limitation on the invention. For example, words such as “distal,” “proximal,” “upper,” “top,” “bottom,” “lower,” “left,” “right,” “horizontal,” “vertical,” “upper,” and “lower”, or other like terminology merely describe the configuration shown in the figures. The referenced components may be oriented in an orientation other than that shown in the drawings and the terminology, therefore, should be understood as encompassing such variations unless specified otherwise.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including” when used herein, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

It will be understood that when an element is referred to as “operatively coupled” to another element, the elements can be formed integrally with each other, or may be formed separately and put together. Furthermore, “operatively coupled” to can mean the element is directly coupled to the other element, or intervening elements may be present between the elements. Furthermore, “operatively coupled” may mean that the elements are detachable from each other, or that they are permanently operatively coupled together.

When components are described as being parallel or perpendicular to other components, it should be understood that this many encompass the components being exactly parallel or perpendicular, or generally parallel or perpendicular in which the components deviate from exactly parallel or perpendicular (e.g., +/−1, 2, 4, 6, 8, 10, 15, 20, 25, or the like degrees from exactly parallel or perpendicular).

Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art appreciate that any arrangement which is calculated to achieve the same purpose may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.

INCORPORATION BY REFERENCE

To supplement the present disclosure, this application further incorporates entirely by reference the following commonly assigned patent applications.

	U.S. Patent Application
Docket Number	Ser. No.	Title	Filed On
014924-000026	To be assigned	ADJUSTABLE FRAME WITH A THERMAL BREAK	Concurrently herewith
014924-000028	To be assigned	ADJUSTABLE FRAME WITH A THERMAL BREAK SEAL	Concurrently herewith
044824-000006	To be assigned	SECURITY FEATURES FOR A SLIDING DOOR SYSTEM	Concurrently herewith

Claims

1. An adjustable door frame for a sliding door, comprising:

a first frame segment having a first molding flange and a first jamb flange; and

a second frame segment having a second molding flange and a second jamb flange;

wherein the first frame segment is adjustable with respect to the second frame segment; and

wherein at least a portion of the first jamb flange and at least a portion of the second jamb flange overlap.

2. The door frame of claim 1, wherein an outer surface of the first jamb flange and an outer surface of the second jamb flange are planer.

3. The door frame of claim 1, further comprising:

one or more segment connectors extending through the first molding flange, the second molding flange, the first jamb flange, or the second jamb flange and into a portion of a support member.

4. The door frame of claim 1, further comprising:

a first molding cap having one or more first cap projections;

wherein the first molding flange comprises one or more first molding projections; and

wherein the one or more first cap projections and the one or more first molding projections operatively coupled the first molding cap to the first molding flange.

5. The door frame of claim 4, wherein the first molding cap comprises:

a molding cap face; and

a jamb cap leg operatively coupled to the molding cap face;

wherein an outer surface of the jamb cap leg is flush with an outer surface of the first jamb flange.

6. The door frame of claim 1, further comprising:

a second molding cap having one or more second cap projections;

wherein the second molding flange comprises one or more second molding projections; and

wherein the one or more second cap projections and the one or more second molding projections operatively couple the second molding cap to the second molding flange.

7. The door frame of claim 6, wherein the second molding cap comprises:

a molding cap face; and

a jamb cap leg operatively coupled to the molding cap face;

wherein a portion of the jamb cap leg overlaps a portion of the second jamb flange.

8. The door frame of claim 7, wherein the first jamb flange overlaps a portion of the second jamb flange, wherein an end of the jamb cap leg is adjacent and end of the first jamb flange, and wherein an outer surface of the first jamb flange and an outer surface of the jamb cap leg are flush.

9. The door frame of claim 1, further comprising:

a first molding cap operatively coupled to the first molding flange, wherein the first molding cap comprises: a first molding cap face; and a first jamb cap leg operatively coupled to the first molding cap face; wherein a portion of the first jamb cap leg overlaps at least a portion of the first jamb flange;

a second molding cap operatively coupled to the second molding flange, wherein the second molding cap comprises: a second molding cap face; and a second jamb cap leg operatively coupled to the second molding cap face;

wherein an outer surface of the second jamb cap leg and the outer surface of the first jamb cap leg are flush.

10. The door frame of claim 9, wherein the first jamb cap leg overlaps the first jamb flange and the second jamb flange, and wherein an end of the first jamb cap leg is adjacent an end of the second jamb cap leg.

11. The door frame of claim 9, wherein the second jamb cap leg overlaps at least a portion of the second jamb flange, and wherein an end of the second jamb cap leg is adjacent an end of the first jam cap leg.

12. The door frame of claim 9, wherein the first jamb flange or the second jamb flange are operatively coupled to each other or a support member using one or more segment connectors;

and wherein the first jamb cap leg or the second jamb cap leg conceal the one or more segment connectors.

13. The door frame of claim 1, wherein the first frame segment comprises:

one or more proximal jamb portions; and

one or more distal jamb portions operatively coupled to the one or more proximal jamb portions;

wherein the one or more proximal jamb portions adjacent the one or more distal jamb portions form one or more jamb channels that receive at least a portion of the second jamb flange.

14. The door frame of claim 1, further comprising:

a receiver comprising: a receiver mount having one or more mount projections; and one or more walls forming a receiver channel;

wherein the first molding flange comprises one or more molding projections;

wherein the one or more mount projections and the one or more molding projections operatively couple the receiver to the first molding flange; and

wherein the receiver channel receives a side of a door.

15. The door frame of claim 1, further comprising:

a header comprising:

a header mount;

a header body operatively coupled to the header mount;

a header cap operatively coupled to the header mount or the header body; and

wherein the header mount, the header body, or the header cap form a header channel; and

wherein the header channel receives upper portion of the door.

16. A door system comprising:

an adjustable door frame comprising: a first frame segment having a first molding flange and a first jamb flange; and a second frame segment having a second molding flange and a second jamb flange; wherein the first frame segment is adjustable with respect to the second frame segment and at least a portion of the first jamb flange and at least a portion of the second jamb flange overlap; wherein the adjustable door frame is operatively coupled to edges of a door opening;

sliding door hardware operatively coupled to a wall or the adjustable door frame; and

a door operatively coupled to the sliding door hardware.

17. The door system of claim 16, wherein an outer surface of the first jamb flange and an outer surface of the second jamb flange are planer.

18. The door system of claim 16, further comprising:

one or more segment connectors extending through the first molding flange, the second molding flange, the first jamb flange, or the second jamb flange and into a portion of a support member.

19. The door system claim 16, further comprising:

a first molding cap having one or more first cap projections;

wherein the first molding flange comprises one or more first molding projections; and

wherein the one or more first cap projections and the one or more first molding projections operatively coupled the first molding cap to the first molding flange.

20. A method of forming a door frame, the method comprising:

adjusting a first frame segment with respect to a second frame segment based on a width of a wall at a door opening, wherein the first frame segment comprises a first molding flange and a first jamb flange, wherein the second frame segment comprises a second molding flange and a second jamb flange, and wherein at least a portion of the first jamb flange and at least a portion of the second jamb flange overlap; and

securing the first frame segment and the second frame segment to the wall at the door opening.