DOOR-READY MOLDING

Abstract

A door system including a primary door molding attachable to a primary door frame, the primary door molding including a first vertical member and a first hinge member extending from the first vertical member. One of a horizontal member from which the first vertical member downwardly extends and the first vertical member includes a first rotatably engageable element, and the first hinge member includes a second rotatably engageable element vertically spaced from the first rotatably engageable element.

Claims

1. A door system comprising: a door molding attachable to a door frame, the door molding comprising: a first vertical member; and a first hinge element extending from the first vertical member, the first hinge element comprising: a first mounting member extending at an angle from a second mounting member, wherein at least one of the first and second mounting members comprises at least one mounting aperture; and a pin-receiving member adjacent to the first and second mounting members.

2. The door system of claim 1, wherein the first mounting member comprises a first face that is perpendicularly arranged relative to a second face of the second mounting member.

3. The door system of claim 1, wherein the first vertical member comprises a recess into which the first hinge element is at least partially insertable.

4. The door system of claim 1, in combination with a fastener to correspond with the at least one mounting aperture of at least one of the first and second mounting members.

5. The door system of claim 1, wherein the pin-receiving member comprises a bushing.

6. The door system of claim 1, wherein the first and second mounting members each comprise the same number of mounting apertures.

7. A mounting adaptor for locating a door molding relative to a vertical door frame member, the mounting adaptor comprising: a locator segment configured to contact an inner portion of the vertical door frame member; a channel segment extending from the locator segment, wherein the channel segment is positionable between an inner portion of the door molding and an outer portion of the vertical door frame member; and a holding segment extending from the channel segment.

8. The mounting adaptor of claim 7, in combination with a door molding comprising an angled mounting adaptor channel, wherein at least one of the channel segment and the holding segment are positionable within the angled mounting adaptor channel.

9. The combination of claim 8, further comprising at least one of: a first fastener that is extendable through the channel segment and into the vertical door frame member; and a second fastener that is extendable through the holding segment and into the door molding.

10. The mounting adaptor of claim 7, wherein the locator segment and the holding segment extend from the channel segment in generally parallel and opposite directions.

11. The mounting adaptor of claim 7, wherein the mounting adaptor comprises a latch-side mounting adaptor configured for locating a latch side of the door molding relative to a latch side of a door frame.

12. The mounting adaptor of claim 7, wherein the mounting adaptor comprises a hinge-side mounting adaptor configured for locating a hinge side of the door molding relative to a hinge side of a door frame.

13. A head support piece for attaching a top door molding to a horizontal door frame member, the head support piece comprising: an extending member comprising at least a portion that is positionable between the top door molding and the horizontal door frame member; and a channel member extending from the extending member on a first side of the extending member that is opposite the horizontal door frame member.

14. The head support piece of claim 13, further comprising a head member extending from a first portion of the extending member on a second side of the extending member that is opposite the first side.

15. The head support piece of claim 13, further comprising a secondary channel member extending from a second portion of the extending member that is spaced from a first portion.

16. The head support piece of claim 13, wherein the channel member comprises a recessed portion.

17. The head support piece of claim 14, in combination with a top door molding and a horizontal door frame member, wherein the head member is positionable adjacent to the horizontal door frame member, and wherein the channel member is positionable within a recess of the top door molding.

18. The combination of claim 17, further comprising: a first fastener extendable through the head member and into the horizontal door frame member; and a second fastener extendable through a recessed portion of the channel member and into the top door molding.

19. The head support piece of claim 13, in combination with a top door molding, wherein the top door molding comprises: a first pocket adjacent to a first end of the top door molding; and a second pocket adjacent to a second end of the top door molding that is spaced from the first end; wherein one of the first and second pockets is configured to receive a pivot member and wherein the other of the first and second pockets is configured to receive one of a pivot member and a plug member.

20. The combination of claim 19, wherein the first and second pockets comprise generally the same peripheral shape to interchangeably receive the pivot member and the plug member.

21. The head support piece of claim 13, in combination with a door closer mechanism, wherein the door closer mechanism comprises: a door closer arm comprising a slide element that is positionable within the channel member and moveable along at least a portion of a length of the channel member; and a door closer engaged with the door closer arm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention will be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views, and wherein;

[0026] FIG. 1 is a front view of a primary/secondary door system as assembled with primary and secondary doors in a closed position;

[0027] FIG. 2 is an isometric view of a primary/secondary door system as assembled with primary and secondary doors in a closed position;

[0028] FIG. 3 is an exploded isometric view of a primary/secondary door system with the primary door in a closed position;

[0029] FIGS. 4a, 4b, and 4c are cross-sectional views of the primary/secondary door system of FIG. 1 taken along section line A-A (FIG. 4a), along with enlarged views of a secondary door latch mechanism and a latch-side molding (FIG. 4b) and of a hinge-side molding (FIG. 4c);

[0030] FIGS. 5a, 5b, and 5c are cross-sectional views of the primary/secondary door system of FIG. 1 taken along section line B-B (FIG. 5a), along with enlarged views of a top molding and top details of a secondary door (FIG. 5b) and of bottom details of a secondary door (FIG. 5c);

[0031] FIGS. 6a and 6b are isometric views of a primary/secondary door system as assembled with primary and secondary doors in an open position (FIG. 6a) and an enlarged view of a bottom hinge mechanism with a cutaway of the hinge pin mechanism of the secondary door (FIG. 6b);

[0032] FIGS. 7a and 7b are isometric views of a primary/secondary door system as assembled with primary and secondary doors in an open position (FIG. 7a) and an enlarged view of a bottom hinge mechanism with the secondary door removed (FIG. 7b);

[0033] FIGS. 8a and 8b are isometric views of a primary/secondary door system as assembled with primary and secondary doors in an open position (FIG. 8a) and an enlarged view of a top hinge mechanism with a cutaway of the hinge pin mechanism of the secondary door (FIG. 8b);

[0034] FIGS. 9a and 9b are isometric views of a primary/secondary door system as assembled with primary and secondary doors in an open position (FIG. 9a) and an enlarged view of a top hinge mechanism with the secondary door removed (FIG. 9b);

[0035] FIG. 10 is an exploded isometric view of a primary/secondary door system with the primary door in a closed position;

[0036] FIGS. 11a, 11b and 11c are cross-sectional views of the primary/secondary door system of FIG. 10 taken along a section line in the same location as section line A-A of FIG. 1 (FIG. 11a), and enlarged views of a secondary door latch mechanism and a latch-side molding (FIG. 11b) and of a hinge-side molding (FIG. 11c);

[0037] FIGS. 12a, 12b and 12c are cross-sectional views of the primary/secondary door system of FIG. 10 taken along a section line in the same location as section line B-B of FIG. 1 (FIG. 12a), and enlarged views of a top molding and top details of a secondary door (FIG. 12b) and of bottom details of a secondary door (FIG. 12c);

[0038] FIG. 13 is an exploded view of a primary/secondary door system with the primary door in a closed position;

[0039] FIGS. 14a, 14b and 14c are horizontal cross-sectional views of the primary/secondary door system of FIG. 13 taken along a section line in the same location as section line A-A of FIG. 1 (FIG. 14a) and enlarged views of a secondary door latch mechanism and a latch-side molding (FIG. 14b) and of a hinge-side molding (FIG. 14c);

[0040] FIGS. 15a, 15b and 15c are vertical cross-sectional views of the primary/secondary door system of FIG. 13 taken along a section line in the same location as section line B-B of FIG. 1 (FIG. 15a), and enlarged views of a top molding and top details of a secondary door (FIG. 15b) and of bottom details of a secondary door (FIG. 15c);

[0041] FIG. 16 is a cross-section of a mounting adapter of the type illustrated in FIG. 13;

[0042] FIGS. 17a, 17b, and 17c are vertical cross-sectional views of the primary/secondary door system of FIG. 1 taken along section line C-C (FIG. 17a), along with enlarged views of a top molding and top details of a secondary door (FIG. 17b) and of bottom details of a secondary door (FIG. 17c);

[0043] FIG. 18 is an isometric view of an embodiment of a primary/secondary door system as assembled with primary and secondary doors in a closed position;

[0044] FIG. 19 is a front view of an embodiment of a primary/secondary door system as assembled with primary and secondary doors in a closed position;

[0045] FIG. 20 is an exploded isometric view of the secondary door and primary door molding of FIGS. 18 and 19;

[0046] FIGS. 21a and 21b are perspective views of a portion of a lower corner at the hinge side of a primary door molding;

[0047] FIG. 22 is a cross-sectional view of a portion of the primary/secondary door system of FIG. 19 taken along section line E-E;

[0048] FIG. 23 is a cross-sectional view of a portion of the primary/secondary door system of FIG. 19 taken along section line D-D;

[0049] FIGS. 24a and 24b are alternative cross-sectional views of a portion of the primary/secondary door system of FIG. 19 taken along section line E-E;

[0050] FIGS. 25a and 25b are alternative cross-sectional views of a portion of the primary/secondary door system of FIG. 19 taken along section line F-F;

[0051] FIG. 26 is a cross-sectional view of a portion of the primary/secondary door system of FIG. 19 taken along section line F-F;

[0052] FIGS. 27a and 27b are perspective views of the bottom side of a top molding of a primary/secondary door system at a top hinge-side corner and a latch-side corner, respectively;

[0053] FIG. 28 is a cross-sectional view of a portion of the primary/secondary door system of FIG. 19 taken along section line E-E; and

[0054] FIG. 29 is an isometric view of a latch plate area of the latch-side molding of the primary/secondary door system of FIG. 19.

DETAILED DESCRIPTION

[0055] The present disclosure describes primary/secondary door systems comprising primary door molding elements configured for mounting a secondary door adjacent to a primary door without requiring separate installation of a secondary door frame. The present primary/secondary door systems comprise a primary door frame (typically including hinge- and latch-side jambs, head, and sill) and the primary door molding (typically including hinge-side and latch-side molding and top molding) attached to each other. Optionally, these components form an integral construction. The primary/secondary door systems can additionally include a primary door rotatably attached by hinges or another attachment system to the primary door frame.

[0056] One or more secondary doors may be provided as part of a package or kit with the primary/secondary door system such that the building contractor or consumer may choose one or more coordinated doors in a system so that they can easily install a secondary door at a desired time. In other situations, a contractor provides and installs a “door-ready molding” to the primary door frame and a consumer can later purchase and install a secondary door. In some embodiments, one or more secondary doors may be changed seasonally by the consumer. Because installation is straightforward and generally able to be performed by a single person, it is therefore easy to remove and replace secondary doors, as desired. An embodiment of primary and secondary doors are hinged on the same side, (i.e., right or left), with the primary door opening inward and the secondary door opening outward, although opposite-side hinges are also contemplated.

[0057] In embodiments, primary door molding of the primary/secondary door system is configured to perform the functions of external molding (brick molding), including bridging the gap between the primary door frame and the building structure both to help prevent ingress of wind, water, insects or animals and to provide an attractive appearance, positioning the door system properly with respect to the building structure, and providing a surface against which the exterior cladding of the structure (brick, stone, vinyl or cement siding, cedar shingles, and the like) may be installed and sealed. Optionally, the primary door molding may be caulked after installation of the door system to assist in these functions. The primary door molding may be optionally anchored or attached to the building surface after installation of the door system. The primary door molding may have decorative cross-sectional profiles, including combinations of millwork features such as flutes, ogees, quarter-round features, and the like, and may additionally include decorative corner features. The primary door molding sections may have the same or contrasting cross-sectional profiles and may be adapted to accept add-on pieces for additional modification of appearance or style.

[0058] In addition, the primary door molding of the primary/secondary door systems of the present disclosure are configured to receive a secondary door, such that the installation of a secondary door frame in order to support a secondary door is unnecessary. The primary door molding can include multiple frame components, such as a hinge-side molding and/or top molding configured for mounting secondary door hinges or equipped with rotatably engageable elements that form a part of a secondary door hinge. In some embodiments, the hinge-side molding and/or top molding include one or more hinge pin receivers (typically holes or depressions), optionally fitted with bushings, positioned and adapted to receive one or more hinge pins mounted on a secondary door to form hinges. Alternatively, hinge pins may be mounted on the hinge-side molding or hinge end of the top molding and corresponding hinge pin receivers and bushings may be provided in the secondary door, or the secondary door may include one hinge pin and one hinge pin receiver.

[0059] The primary door molding may include a latch-side molding adapted to engage with latch mechanisms of a secondary door, such as the bolt of the secondary door latch. In exemplary embodiments, a latch-side molding includes a door latch channel positioned to receive the bolt of the secondary door latch. In exemplary embodiments, the latch-side molding includes a strike plate or is configured for mounting a strike plate positioned to receive the bolt of the secondary door latch. Alternatively, the primary door molding and secondary door may be rotatably connected by one or more traditional hinges comprising a leaf attached to the hinge-side molding, a leaf attached to the hinge side of the secondary door, and a hinge pin which is dropped through the hinge leaves once the door is placed near the hinge-side jamb and the hinge leaves are aligned.

[0060] The primary door molding may be mounted to the primary door frame by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof. Optionally, the primary door molding and primary door frame are permanently joined (such as by welding, permanent adhesive, permanent fasteners, or methods that cannot be reversed non-destructively) to form an integral construction. Optionally, the primary door molding and primary door frame are joined by projections such as hooks or pegs to engage receiving features such as V-shaped or keyhole-shaped holes. In some embodiments, including the embodiment illustrated in FIGS. 10 through 12c discussed below, the primary door molding includes mounting flanges which extend in a direction generally orthogonal to the plane of the closed position of the secondary door along an inner portion of the hinge-side and latch-side jambs. The primary door molding may be attached to the primary door frame by attachment of the mounting flanges to the inner portions of the hinge- and latch-side jambs.

[0061] In embodiments, including the embodiment illustrated in FIGS. 13 through 16 discussed below, a mounting adapter is additionally provided to assist in a desirable door installation that allows for at least some adjustability. Like the mounting flange discussed above, the mounting adapter may include an orthogonal portion which extends in a direction generally orthogonal to the plane of the closed position of the secondary door along an inner portion of the hinge- and latch-side jambs and may be attached to the inner portion of the hinge- and latch-side jambs. The mounting adapters additionally include channel segments which are positionable in mounting adapter channels provided in the hinge and/or latch-side moldings. This embodiment allows the primary door molding some degree of motion relative to the primary door frame so that the position and fit of the molding may be adjusted after installation, vertically or laterally, and the hinge- and latch-side moldings may be adjusted to true vertical orientation. Optionally, after installation of the primary/secondary door system and adjustment of the position of the primary door molding, the primary door molding may be affixed directly to elements of the primary door frame to eliminate this adjustability or play.

[0062] The various parts and elements of the primary/secondary door system may be made of any suitable materials, which are not particularly limited. Such materials may include exemplary materials including wood, metal (such as aluminum or steel), extruded or molded plastics, resin/matrix composites such as fiberglass, other suitable materials, or a combination of these or other suitable materials.

[0063] Referring to exemplary FIGS. 1 through 3, an assembled primary/secondary door system 10 is illustrated, which includes a secondary door 20 that is commonly referred to as a screen door, a storm door, or security door, for example. Secondary door 20 may be of any suitable style and may include single or multiple transparent panels, opaque panels, screening panels, metal or mesh grilles, and the like. In this illustrated embodiment, secondary door 20 comprises a glass panel through which primary door 30 is visible. Primary/secondary door system 10 additionally includes a hinge-side jamb 40, a latch-side jamb 50, a head 60, and a sill 140, which together comprise a primary door frame. Elements of the primary door frame may be fastened together by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof.

[0064] Primary/secondary door system 10 additionally comprises a hinge-side molding 70, a latch-side molding 80, and a top molding 90, which together comprise a primary door molding 90. Elements of the primary door molding 90 may be fastened together by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof. The primary door molding 90 may additionally utilize intermediate structures in combination with mechanisms such as inserts comprising two perpendicular legs positioned in each corner. Likewise, the primary door molding 90 may be attached to the primary door frame by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like; adhesives; welding; or combinations thereof.

[0065] In embodiments, the combination of the primary door molding 90 and the primary door frame are configured as an integral construction. In some embodiments, hinge-side jamb 40 and hinge-side molding 70 are a unitary article (i.e. a single unified part such as would be made in a single molding, extrusion, or machining). Similarly, latch-side jamb 50 and latch-side molding 80 may be a unitary article, and/or head 60 and top molding 90 may be a unitary article. In embodiments, it is possible for only a single molding to be provided that cooperates with other structure(s) for mounting of a secondary door.

[0066] In an embodiment, hinge-side molding 70 comprises an extending hinge plate or element 100 with a rotatably engageable element (e.g. an aperture or pin-receiving member) that receives a hinge pin (not visible in FIGS. 1-3) extending from secondary door 20. In embodiments, the hinge plate or element 100 extends from a distal end of the hinge-side molding 70; however, the hinge plate or element 100 can be spaced vertically from the distal end of the hinge-side molding.

[0067] Secondary door 20 includes secondary door hardware 110 with secondary door exterior handle 120 and secondary door interior handle 130, which may include any of a number of available door hardware configurations. The present figures illustrate a left-hinge out-swinging secondary door 20 and a left-hinge in-swinging primary door 30; however, it is understood that any combinations of left-hinge and right-hinge primary and secondary doors are also contemplated. Optionally, the position of the inner edge of at least one of hinge-side molding 70 and latch-side molding 80, are adjustable (e.g., by provision of a telescoping or extending sections, so that the inside edge of the molding can be adjusted before, while, or after secondary door is attached to the molding in order to get the proper spacing and clearance between the molding and the secondary door).

[0068] FIGS. 4a, 4b and 4c include cross-sectional views taken along section line A-A of FIG. 1 of a secondary door latch mechanism and latch-side molding 80 (FIG. 4b) and of hinge-side molding 70 (FIG. 4c). With particular reference to FIG. 4b, a secondary door exterior handle 120 and secondary door interior handle 130 may be used to operate secondary door latch mechanism 150 to withdraw secondary door latch bolt 160. Secondary door latch bolt 160 engages with secondary door latch channel 170 to hold the secondary door 20 closed. In some embodiments, secondary door latch channel 170 is continuous down the length of latch-side molding 80 such that latch-side molding 80 has a constant cross section and may therefore be produced by a continuous process such as an extrusion process. In various embodiments, one, two, or all three of hinge-side molding 70, latch-side molding 80, and top molding 90 have a constant cross section and may therefore be produced by a continuous process such as an extrusion process. In embodiments, hinge-side molding 70 may also include secondary door latch channel 170 to accommodate left-opening and right-opening door installations, and so that hinge-side molding 70 and latch-side molding 80 have the same profile (flipped end to end) and can therefore be made in the same process.

[0069] With reference to FIGS. 4b and 4c, weatherstrip channels 180 can be provided to hold flexible weatherstrip (not shown) so that secondary door 20, acting together with primary door molding 70, 80, and 90, may provide a barrier to wind, precipitation, and insects and other pests. In the depicted embodiment, weatherstrip channels 180 are located so that weatherstrip is not visible when secondary door 20 is closed. Since weatherstrip is often not paintable, this reduces the amount of visible surface and enables a more attractive door system having no visible unpaintable surfaces (in the closed position), other than transparent or screen panels (when present).

[0070] FIGS. 5a, 5b and 5c include cross-sectional views taken along section line B-B of FIG. 1 and illustrate top molding 90 and top details of secondary door 20 (FIG. 5b) and bottom details of secondary door 20 (FIG. 5c). In the illustrated embodiment, weatherstrip channels 180 are located such that weatherstrip is not visible when secondary door 20 is closed, as addressed above. A door closer arm 190 and door closer 195 optionally form a part of a door-mounted door closer mechanism. Door closer arm 190 is visible in an extended position in FIGS. 6a, 7a, 8a, and 9a. With a door-mounted door closer system, the closer is concealed in the top of the door. Alternately, a frame-mounted door closer system may be used, in which case the closer may be housed in the top molding, or the door closer may be omitted. In other alternate embodiments, closer arm 190, which is a straight arm, may be replaced with a hinged arm made from two or more segments. Door closers disclosed in U.S. patent application Ser. Nos. 15/382,275, 15/385,091, 15/911,639, 15/911,690, and 16/914,850, which are incorporated herein by reference, may be used in the practice of the present door systems. The primary door may additionally be equipped with a door-mounted or frame-mounted closer.

[0071] FIGS. 6a and 7a are views of an exemplary door system with primary and secondary doors in an open position, and FIGS. 6b and 7b are enlarged views of a bottom hinge mechanism. In particular, FIG. 6b illustrates a cutaway of the bottom hinge area with a hinge pin of a secondary door 20 engaged with the hinge mechanism, and FIG. 7b is an enlarged view of elements of a bottom hinge mechanism without the secondary door. The bottom hinge mechanism includes a rotatably engageable element in the form of a hinge pin 230 extending from the secondary door 20 and an optional bottom hinge bushing 240 installed in an aperture (not visible) provided in the hinge plate 100 to form a rotatably engageable element or hinge pin receiver. Optionally, the hinge-side molding 70 and hinge plate 100 form an integral construction. Bottom hinge pin 230 engages with bottom hinge bushing 240 to form a bottom hinge which bears the greater part of the weight of and provides an axis for rotation of secondary door 20.

[0072] With regard to the bottom hinge mechanism or rotatably engageable element, it is contemplated that such a feature is a part of the sill of a primary door frame rather than a hinge plate as described above. In such a configuration, the sill can include either an extending pin or an aperture (which can include a bushing) that is engageable with a corresponding aperture or pin of a secondary door for rotatable engagement between the components. The top of the secondary door will then be rotatably engageable with either a rotatably engageable element of the top molding or of a hinge plate extending from an upper area of a hinge-side molding.

[0073] FIGS. 8a, 8b, 9a, and 9b illustrate a top hinge mechanism of one embodiment of an assembled primary/secondary door system 10. FIG. 8b is an enlarged view of the top hinge mechanism with a cutaway of the hinge pin mechanism internal to secondary door 20. FIG. 9b is an enlarged view of elements of a top hinge mechanism without the secondary door. The top hinge mechanism includes a rotatably engageable element in the form of a top hinge pin 200, a top hinge bushing 210 installed in an aperture (not visible) provided in the top molding 90 to form a hinge pin receiver, and a top hinge pin biasing member 220. Hinge pin biasing member 220, which can include a spring, urges top hinge pin 200 to an extended position. During installation, after a bottom hinge pin (e.g., hinge pin 230) is engaged with a rotatably engageable element (e.g., a bottom hinge bushing), top hinge pin 200 may be pushed against hinge pin biasing member 220, located in alignment with top hinge bushing 210, and allowed to revert to an extended position to engage with the rotatably engageable element to form a top hinge. However, it is understood that both the bottom hinge pin 230 and top hinge pin 200 may be retractable and extendable, or that only the bottom hinge pin 230 is retractable and extendable.

[0074] FIGS. 17a, 17b and 17c include cross-sectional views taken along section line C-C of FIG. 1 and illustrate enlarged views of a top molding 390 engaged with a rotatably engageable element of a secondary door (FIG. 17b) and bottom details of a rotatably engageable element of a secondary door engaged with a hinge plate 400 (FIG. 17c). In particular, FIG. 17b illustrates top molding 390 with an aperture in which a bushing 310 is positioned. As shown, the bushing 310 is tapered to provide a cone-shaped inner aperture configured to accept an inserted pin 350 with a tapered distal end. Similarly, FIG. 17c illustrates a hinge plate 400 that extends from a vertical molding and that includes an aperture in which a bushing 340 is positioned. As shown, the bushing 340 is tapered to provide a cone-shaped inner aperture configured to accept an inserted pin 352 with a tapered distal end. The tapered portions of the pins 350, 352 cooperate with the tapered portions of their respective bushings 310, 340 to help the pins 350, 352 self-align and self-center themselves, thereby providing for an easier installation. While these tapered members are illustrated both at the top and the bottom of the hinge-side molding 70, it is understood that such tapered elements may only be provided at one of these locations.

[0075] With further reference to FIG. 17a, an optional top molding extender 392 is engaged with the top molding 390. As shown, the top molding extender 392 is configured with multiple extensions 394 that are adjustably engageable with structure of the top molding 390 and/or other structure to achieve a desired vertical positioning of the top molding extender relative to the structure to which the door molding is installed. Other top molding extender positioning mechanisms are contemplated, including but not limited to detents, mating grooves, fasteners, friction, adhesives, and the like. The top molding extender is configurable to accommodate installations that involve differing wall depths and door heights

[0076] In an alternate embodiment, the top hinge pin receiver is configured similar to the bottom hinge pin receiver using an upper hinge plate that extends from hinge-side molding 70 and which is spaced vertically from the hinge plate 100 positioned at the lower portion or distal end of the molding 70. In such an embodiment, the top hinge pin 200 will be engaged with a rotatably engageable element or aperture/bushing of the hinge plate rather than an aperture/bushing of the top molding 90. In another embodiment, one or more of the hinge plates and hinge pin receivers may be located at an intermediate position along the hinge side molding, with rotatably engageable hinge pins located at corresponding along the hinge-side edge of the secondary door. In yet another alternate embodiment, the top molding 90 comprises top hinge pin receivers or rotatably engageable elements on both left and right sides to accommodate left-opening and right opening door installations.

[0077] FIGS. 10 through 12c represent an alternate mechanism for attachment of the primary door molding to the primary door frame. In this embodiment, latch-side molding 80 comprises a latch-side mounting flange 250 which extends in a direction generally orthogonal to the plane of the closed position of the secondary door 20 and contacts an inner portion of latch-side jamb 50. Similarly, hinge-side molding 70 comprises a hinge-side mounting flange 260 which extends in a direction generally orthogonal to the plane of the closed position of the secondary door and contacts an inner portion of hinge-side jamb 40. In various embodiments, mounting flanges 250, 260 are attachable to jambs 40, 50 by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof. Latch-side molding 80 and latch-side mounting flange 250 may comprise a unitary construction, although they may be separate pieces joined together. Similarly, hinge-side molding 70 and hinge-side mounting flange 260 may comprise a unitary construction, although they may be separate pieces joined together. Other elements of FIGS. 10 through 12c can include similar features and functionality as described above with regard to FIGS. 1-9.

[0078] FIGS. 13 through 16 represent another feature that can be used for attachment of a primary door molding to a primary door frame. This embodiment utilizes mounting adapters such as a latch-side mounting adapter 270, which is illustrated in cross-section in FIG. 16. In particular, latch-side mounting adapter 270 includes attachment segment of a latch-side mounting adapter 271 which, when installed, extends in a direction generally orthogonal to the plane of the closed position of the secondary door and contacts an inner portion of latch-side jamb 40. Latch-side mounting adapter 270 includes a channel segment of latch-side mounting adapter 272 which, when installed, resides in a latch-side mounting adapter channel 290. After installation, a holding segment 273 of latch-side mounting adapter 270 maintains latch-side mounting adapter 270 in the latch-side mounting adapter channel 290 in a lateral direction. The preceding description applies similarly to a hinge-side mounting adapter 280 (which can have the same general configures as the latch-side mounting adapter 270) and a corresponding hinge-side mounting adapter channel 300.

[0079] Latch-side and hinge-side mounting adapters 270, 280 may be identical if turned end-to-end, as they are in the depicted embodiment, which can be useful for design and manufacturing considerations. Mounting adapters 270, 280 are attached to jambs 40, 50 by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof. Mounting of the primary door molding on the primary door frame by the mechanism of mounting adapters 270, 280 traveling in mounting adapter channels 290, 300 permits a limited amount of vertical and lateral movement of the primary door molding relative to the primary door frame. Optionally, after installation of primary/secondary door system 10 and adjustment of the position of the primary door molding, elements of the primary door molding may be affixed directly to elements of the primary door frame by any of the attachment mechanisms described above to prevent further movement of the primary door molding. Other elements of FIGS. 13 through 15c can include similar features and functionality as described above with regard to FIGS. 1-9.

[0080] A primary/secondary door system according to an embodiment of the present disclosure includes the primary door frame (which includes hinge- and latch-side jambs, head, and sill) and the primary door molding (which includes hinge- and latch-side molding and top molding) assembled together. Optionally, these components form an integral construction. The primary/secondary door system additionally includes a primary door rotatably attached by hinges to the primary door frame. The primary/secondary door system (minus secondary door) can be installed (e.g., in a door opening in a commercial or residential building) in the customary manner for a primary door. Optionally, the primary door molding is anchored or attached to the building surface. The primary/secondary door system is then ready for mounting of the secondary door on the primary door molding.

[0081] Referring to FIGS. 18 and 19, an embodiment of an assembled primary/secondary door system 410 is illustrated, which generally includes a secondary door 420 through which a primary door 430 is visible, and FIG. 20 is an exploded isometric view of the secondary door and primary door molding of FIGS. 18 and 19. In this embodiment, the secondary door 420 includes a glass panel; however, the secondary door 420 can include a number of different configurations, such as a screen door, a storm door, or security door, for example, and may include single or multiple transparent panels, opaque panels, screening panels, metal or mesh grilles, and the like.

[0082] Primary/secondary door system 410 further includes a hinge-side jamb 440, a latch-side jamb 450, a head 460, and a sill 442, which together comprise a primary door frame 435. Elements of the primary door frame 435 may be fastened together and/or to the building opening by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, or may additionally or alternatively use fastening mechanisms including adhesives, welding, or combinations thereof.

[0083] Primary/secondary door system 410 additionally includes a primary door molding 465 that is generally made up of a hinge-side molding 470, a latch-side molding 480, and a top molding 490. Elements of the primary door molding 465 may be fastened together by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, or may additionally or alternatively use fastening mechanisms including adhesives, welding, or combinations thereof. The primary door molding 465 may additionally utilize intermediate structures in combination with mechanisms such as inserts comprising perpendicular legs positioned at one or more corners. As shown, the primary door molding 465 may be attached to the primary door frame 435 by any suitable mechanism, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, or may additionally or alternatively use adhesives, welding, or combinations thereof.

[0084] In some embodiments, a combination of the primary door molding 465 and the primary door frame 435 are configured as an integral construction. In other embodiments, hinge-side jamb 440 and hinge-side molding 470 are a unitary article (i.e., a single unified part such as would be made in a single molding, extrusion, or machining). Similarly, latch-side jamb 450 and latch-side molding 480 may be a unitary article, and/or head 460 and top molding 490 may be a unitary article. In embodiments, it is possible for only a single molding to be provided that cooperates with other structure(s) for mounting of a secondary door 420.

[0085] The illustrated embodiment of primary/secondary door system 410 illustrates a left-hinge out-swinging secondary door 420 and a left-hinge in-swinging primary door 430; however, it is understood that any combinations of left-hinge and right-hinge primary and secondary doors are also contemplated. Optionally, the position of the inner edge of at least one of hinge-side molding 470 and latch-side molding 480 are adjustable (e.g., by provision of a telescoping or extending sections that allow the inside edge of the molding to be adjusted before, during, or after attachment of the secondary door 420 to the primary door molding 465 in order to achieve a desired spacing and clearance between the primary door molding 465 and the secondary door 420).

[0086] FIGS. 21a and 21b are enlarged views of a portion of the bottom or distal portion of the hinge-side molding 470 with an embodiment of a hinge plate or element 500 at a generally distal end of the hinge-side molding 470 and with fasteners 510 prior to fastening and after fastening, respectively. It is understood that while the hinge plate or element 500 is shown at the distal end of molding 470, the hinge plate or element 500 can instead be spaced vertically from the distal end of the hinge-side molding 470.

[0087] The hinge-side molding 470 includes a recessed area into which the hinge plate or element 500 is at least partially insertable. Hinge plate or element 500 includes a first mounting member 504 adjacent to a second mounting member 506, both of which extend in generally the same vertical direction as the hinge-side molding 470 in which the hinge plate or element 500 is positioned. First mounting member 504 is generally perpendicular to second mounting member 506 to provide for attachment of the hinge plate or element 500 to surfaces that are generally perpendicular to each other.

[0088] As shown, first and second mounting members 504, 506 each have two apertures 508 spaced vertically from each other. Although apertures 508 are shown as being positioned directly above each other, they may instead be offset or otherwise arranged relative to each other relative to each of the mounting members 504, 506. In other embodiments, each of the mounting members 504, 506 can include more or less than two apertures 508. Both of the mounting members 504, 506 can include the same number of apertures 508 as each other or can instead include different numbers of apertures 508. The hinge plate or element 500 is provided with multiple fasteners 510 to correspond with each of the apertures 508, which may include screws, nails, or other fastener configurations that are configured extend through the apertures 508 to attach the hinge plate or element 500 to the adjacent structure, such as rivets, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof. In cases where adhesives, welding, or other similar fastening techniques are used, apertures 508 may not be provided through the mounting members 504, 506.

[0089] The hinge plate or element 500 further includes a pin-receiving member 520 with an aperture 522 that is configured to receive a bottom hinge pin 502 (visible in FIG. 20) extending from secondary door 420. The hinge plate or element 500 may further optionally include a bottom hinge bushing 522 within an aperture (not illustrated). In an embodiment, hinge pin 502 is engageable with the aperture (and optionally bottom hinge bushing 522) to form a bottom hinge which bears the greater part of the weight of and provides an axis for rotation of secondary door 420. The top portion of the secondary door 420 can include a top hinge pin 503 (visible in FIG. 20) rotatably engageable with either a rotatably engageable element of the top molding 490 or of a hinge plate extending from an upper area of a hinge-side molding 470. Such a rotatable engagement of the top portion of the secondary door 420 can have the same or a similar configuration to the hinge plate or element 500 or can have a different configuration.

[0090] With regard to the bottom hinge mechanism or rotatably engageable element, it is contemplated that such a feature is a part of the sill of a primary door frame rather than a hinge plate or element as described above. In such a configuration, the sill can include either an extending pin or an aperture (which can include a bushing) that is engageable with a corresponding aperture or pin of a secondary door for rotatable engagement between the components. The top of the secondary door will then be rotatably engageable with either a rotatably engageable element of the top molding or of a hinge plate extending from an upper area of a hinge-side molding.

[0091] FIG. 22 illustrates a latch-side mounting adapter 530, which is provided as a stiffener and is used to locate the latch-side molding 480 in relation to latch-side jamb 450. Latch-side mounting adapter 530 includes a locator segment 532 which, when installed, extends in a direction generally orthogonal to the plane of the closed position of a secondary door and contacts an inner portion of latch-side jamb 450. Latch-side mounting adapter 530 further includes a channel segment 534 and a holding segment 536 which, when installed, reside in an angled latch-side mounting adapter channel 538. After installation, holding segment 536 of latch-side mounting adapter 530 maintains latch-side mounting adapter 530 in the latch-side mounting adapter channel 538 in a lateral direction. The preceding description applies similarly to a hinge-side mounting adapter 550, illustrated in FIG. 23, which can have the same general configuration as the latch-side mounting adapter 530 and a corresponding angled hinge-side mounting adapter channel 558. In addition, holding segment 536 locates latch-side molding 480 in relationship to latch-side jamb 450 and provides a structure to attach latch-side molding 480 to primary/secondary door system 410 while also strengthening and stiffening latch-side molding 480.

[0092] Latch-side and hinge-side mounting adapters 530, 550 may be identical if turned end-to-end (or “mirrored”), as illustrated, which can be useful for design and manufacturing considerations. Mounting adapters 530, 550 are configured for attachment to jambs 440, 450, and hinge-side molding 470 and latch-side molding 480 are configured for attachment to mounting adaptors 530, 550 by any suitable mechanism, including mechanical fastening devices such as the illustrated screws 540, and/or rivets, nails, staples, dowels, customized mechanical connectors, and the like, and may additionally or alternatively use adhesives, welding, or combinations thereof. Mounting of the primary door molding on the primary door frame by the mechanism of mounting adapters 530, 550 traveling in mounting adapter channels 538,558 permits a limited amount of vertical and lateral movement of the primary door molding relative to the primary door frame 435. Other elements of FIGS. 22 and 23 can include similar features and functionality as described above with regard to FIGS. 18-20.

[0093] Primary/secondary door system 410 includes the primary door frame 435 (which includes hinge-side and latch-side jambs 440, 450, head 460, and sill 442) and the primary door molding 465 (which includes hinge-side and latch-side moldings 470, 480 and top molding 490) assembled together. Optionally, these components form an integral construction. The primary/secondary door system 410 additionally includes a primary door 430 rotatably attached by hinges to the primary door frame 435. The primary/secondary door system 410 (minus secondary door 420) can be installed in a generally customary manner for a primary door (e.g., in a door opening in a commercial or residential building). Optionally, the primary door molding 465 can be anchored or attached to the building surface. The primary/secondary door system 410 is then in a configuration for optional mounting of a secondary door 420 on the primary door molding 465.

[0094] FIGS. 24a and 24b are alternative cross-sectional views of a portion of the primary/secondary door system of FIG. 19 taken along section line E-E, wherein the door system of FIG. 24a is used to fill a wider building opening than the door system of FIG. 24b while using a secondary door having the same width. In particular, FIG. 24a includes a latch-side molding 480 that is wider than the latch-side molding 480 of FIG. 24b. As shown, the same latch-side mounting adapter 530 is used in both embodiments, such that the latch-side moldings 480 are differently positioned relative to the adapter 530 (i.e., shifted in a horizontal direction) to provide for proper positioning of the primary/secondary door systems within the provided building openings and to provide the proper lateral extension of latch-side molding 480 beyond the outside edge of latch-side jamb 450. The preceding description applies similarly to hinge-side molding 470, hinge-side mounting adapter 550, and hinge-side jamb 440.

[0095] Similarly, FIGS. 25a and 25b are alternative cross-sectional views of a portion of the primary/secondary door system of FIG. 19 taken along section line F-F, wherein the door system of FIG. 25a is used to fill a taller building opening than the door system of FIG. 25b while using a secondary door having the same height. In particular, FIG. 25a includes a top molding 490 that is taller than the top molding 490 of FIG. 25b. As shown, a head support piece 600 is engageable with and secured to head 460 of a primary door frame and top molding 490 of a primary door molding of the embodiments of both FIGS. 25a and 25b. The illustrated head support pieces 600 are each configured with a vertically extending member 602 that is longer for the embodiment of FIG. 25a than that of FIG. 25b. In this way, the distance between the illustrated top surface of the head 460 and the illustrated top surface of the top molding 490 is the same in both embodiments of FIGS. 25a and 25b, and for other top moldings having different heights than those illustrated.

[0096] FIG. 26 is a cross-sectional view of a portion of the primary/secondary door system of FIG. 19 taken along section line F-F, which includes head support piece 600 that attaches the top molding 490 to the head 460 of a primary door frame while also strengthening and stiffening top molding 490. As shown, head support piece 600 includes extending member 602 (which extends vertically, in this illustration) positioned between ends of the top molding 490 and the head 460, head member 604 adjacent to one end portion of extending member 602, and a channel member 606 adjacent to a central portion of extending member 602 on the opposite side from the head member 604. Head member 604 is positioned on top of head 460 and is secured to head 460 via a fastener 620 (e.g., a screw), while an inner area of channel member 606 is similarly secured to top molding 490 by a fastener 620 (e.g., a screw).

[0097] Channel member 606 of head support piece 600 serves as a track for a portion of a closer arm that can be positioned therein and slide along its length. As such, channel member 606 includes an optional recessed portion 608 in which the head of fastener 620 can be positioned or recessed relative to the rest of the opening within channel member 606 so that there is no interference or contact between the fastener 620 and the portion of a closer arm positioned in the channel member 606. However, the head support piece 600 can be attached to adjacent structures using other mechanisms that do not have a protruding screw head, including mechanical fastening devices such as screws, rivets, nails, staples, dowels, customized mechanical connectors, and the like, or may additionally or alternatively use adhesives, welding, or combinations thereof, wherein at least some of these attachment mechanisms would not require a recessed portion within the channel member 606.

[0098] Head support piece 600 further includes at least one weatherstrip channel 610 extending from member 602 for sealing a storm door. Weatherstrip channel 610 is illustrated at a distal end of member 602 on the same side as the channel member 606; however, weatherstrip channel 610 can instead be located in a different position on the head support piece 600.

[0099] FIGS. 27a and 27b are perspective views of the bottom side of a top molding 490 of a primary/secondary door system at a top hinge-side corner and a latch-side corner, respectively. Top molding 490 includes recessed channel member 606 described above relative to FIG. 26, for example. Top molding 490 further includes pockets adjacent to each of its ends that can receive either a pivot member 630 (FIG. 27a) or a plug member 632 (FIG. 27b), wherein the pivot member 630 and plug member 632 share similar peripheral geometries. Pivot member 630 may further optionally include a top hinge bushing 634 within an aperture (not illustrated) into which a pin of a secondary door can be inserted to provide the top portion of a hinge. As shown, the pivot member 630 is positioned on the left side of the top molding 490 to provide for left-hand hinging, while the plug member 632 is positioned on the right side of the top molding 490 to cover the pocket opening. However, if it is desired to instead provide for right-hand hinging, the pivot member 630 can be positioned on the right side of the top molding 490, while the plug member 632 would then be positioned on the left side of the top molding 490. Such a plug member 632 is optional, although it can be desirable for aesthetic purposes. In addition, it is possible for the pockets on both ends of the top molding 490 to include a pivot member 630, even though only one of them will be engaged with a pin of a secondary door. Such a configuration and arrangement of the top molding 490, pivot member 630, and plug member 632 offer the ability to provide for either left-hand or right-hand hinging through universal components, thereby avoiding the cost and complexity of unique components for left-hand and right-hand hinging.

[0100] FIGS. 28 and 29 provide a cross-sectional view taken along section line E-E of FIG. 19 and an isometric view of a latch plate area of the latch-side molding 480, respectively. A channel 640 extends along a portion of the height of the latch-side molding 480, and a strike plate 642 is secured within the channel 640 using screws or other fastening means or mechanisms. The strike plate can include two openings 644 spaced vertically from each other to receive a latchbolt and a deadbolt extending from a door, for example, or can include more or less than two openings 644 to receive a different number of latch and lock extensions.

[0101] The present invention has now been described with reference to several embodiments thereof. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. The implementations described above and other implementations are within the scope of the following claims.