A door assembly is shown and described herein. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a mullion. The invention may also be considered a frame member. The frame member may be a mullion and include a core; and a two-piece top piece adjoining the core to form a structural member. The door assembly may further include at least one adjacent panel. The inventions disclosed are also applicable to jambs and window structures. Also disclosed are methods and assemblies for a mullion door frame member.

The present invention provides a door frame comprising of two piece units and the method of installment to provide connection between the casing and the frame with a self-alignment system. This is done by a tongue and groove connection and plurality of prefabricated dowels that are specially formed to engage the grooves provided in the frame through the entire attachment area of the frame units together. The door frame units are being assembled and secured together by providing a solid reinforced assembly. In the door frame system of the present invention a strong square joint can be produced by inserting dowels at critical joints which is significantly stronger fastening mechanism than other fastening means such as nails, staples, etc. Low expansion reinforced foam fills the cavities of the frame and creates a solid bond between door system and casing.

The present invention relates generally to a universal strut for doors and window elements. More particularly, the invention encompasses a universal strut that mates with a first formed member, and a second formed member, and which assembly is used as windows, doors, window frames, and door frames. The invention also provides a method of using the inventive universal strut for applications that require different widths and lengths for a production or customized window, door, window frame, or door frame. The universal strut can also be used as a thermal barrier between the first formed member, and the second formed member. Preferably, the universal strut is made from a non-metallic or thermal barrier material, while the first formed substrate, and the second formed substrate are preferably made from a metallic material. The universal strut allows for the formation of various configurations for the shapes of window and/or door elements.

The present invention relates to a door frame, particularly a door frame for a pre-hung door assembly, which is foldable to minimize storage space and to allow for enhanced logistic efficiencies. The door frame contains parallel, spaced apart, vertical jambs and a horizontal header connecting the top ends of the jambs. Each of the jambs and the horizontal header contains a front section and back section that are hingedly joined so that then can be folded on to each other. The hingedly joined front and back sections allow the door fame to be foldable to minimize space occupied during storage.

Disclosed is a window or door frame assembly having a jamb extension coupling a window or door frame. The window or door frame has a longitudinal member having a surface defining a channel formed along the length of the longitudinal member. A jamb extension having a first face and a second face, a plurality of spaced apart grooves formed on the first face and extending along the length of the jamb extension, with the jamb extension configured to matingly engage the channel. A tooth coupled to the longitudinal member and configured to engage one of the plurality of grooves for coupling the jamb extension to the window or door frame. Also disclosed are kits and process for the window or door frame assembly.

A door assembly is shown and described herein. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a mullion. The invention may also be considered a frame member. The frame member may be a mullion and include a core; and a two-piece top piece adjoining the core to form a structural member. The door assembly may further include at least one adjacent panel. The inventions disclosed are also applicable to jambs and window structures. Also disclosed are methods and assemblies for a mullion door frame member.

There is provided a polymer fabrication method for forming 3-dimensional shapes from a sheet polymer blank (10) by machining at least one re-entrant, elongate groove forming a reduced thickness portion (25) permitting the blank to be folded and having opposed edges (12) at the surface, folding the blank about the groove to form at least a portion of the 3-dimensional shape, the re-entrant of the groove forming an elongate chamber (21) adjacent the reduced thickness portion and opening through an elongate gap (20) between the opposed edges, hot air welding the opposed edges across the gap with filler rod (22), and heating the reduced thickness portion to a selected thermo-reforming temperature via the chamber.

There is provided a polymer fabrication method for forming 3-dimensional shapes from a sheet polymer blank (10) by machining at least one re-entrant, elongate groove forming a reduced thickness portion (25) permitting the blank to be folded and having opposed edges (12) at the surface, folding the blank about the groove to form at least a portion of the 3-dimensional shape, the re-entrant of the groove forming an elongate chamber (21) adjacent the reduced thickness portion and opening through an elongate gap (20) between the opposed edges, hot air welding the opposed edges across the gap with filler rod (22), and heating the reduced thickness portion to a selected thermo-reforming temperature via the chamber.

A door assembly and a frame member for a door assembly. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a pair of side jambs. The invention may also be considered a frame member including a storage compartment. The frame member may include a core; and a top piece adjoining the core to form a structural member. The core and the top piece may be a composite of cellulosic material and at least one other material. The top piece may be a two-piece top piece and may include hollow cavities. Also disclosed are door jamb frame members and mullion frame members.