Abstract
A door frame profile and reinforcement assembly to increase the resistance of an entry door and door frame to forced entry by an intruder. Increased resistance is achieved by fitting and securing a U-shaped bar within a machined slot in the back of the door frame and attaching a shaped plate or plates that fits within the shaped bar and retains the door's throw bolt of the deadbolt and/or latch of the door lock. Optionally, with stronger door frames, the shaped plate alone may suffice, and the plate can be modified to a simple L-shaped form, a portion of which is inserted into a narrow groove which replaces the machined slot.
Claims
1. An entry door frame reinforcement assembly, comprising: a) at least one shaped, generally flat plate adapted to be fastened to the back of an entry door frame adjacent the door latch and/or deadbolt receptacles in said frame, said plate comprising at least one elongated hole extending parallel to the sides of the plate and door frame and adapted to permit positioning and installation in contact with said frame using mechanical fasteners, b) a hole extending through said plate designed and adapted to accommodate said door latch and/or deadbolt when locked, with a support flange extending perpendicular to said plate adapted to fit into a portion of the opening for said door latch and/or deadbolt, and a portion of said plate extending substantially the full length of said plate and bent perpendicular to said plate, forming a flange to permit secure attachment to a groove or slit in said door frame, and further comprising: c) a U-shaped bar having a broad “U” shaped cross section and sufficient holes along the centerline of the length thereof to permit secure installation and fastening in a rectangular groove in the back of said door frame and parallel to the length of said frame, adapted to receive said U-shaped bar, wherein (d) said shaped plate, in place of the perpendicular bend of a portion along its edge, comprises a double 90 degree bend forming a flat offset portion which extends below the plate itself and parallel thereto, being adapted to fit into said U-shaped bar, and fits the bottom surface thereof when said shaped plate is installed adjacent said U-shaped bar to reinforce said door frame adjacent said openings for said latch and/or deadbolt, wherein said shaped plate and said U-shaped bar are held in place by mechanical fasteners.
2. The assembly of claim 1, wherein said shaped plate further comprises an additional 90 degree bend on the edge opposite the latch hole which provides a flat, rectangular offset portion extending below said plate and parallel thereto which is designed and adapted to be inserted into a rectangular groove in the back of the door frame and mechanically fastened to said door frame within said groove.
3. The assembly of claim 1 wherein said groove or slit is formed in the back of said door frame during manufacture.
4. The assembly of claim 1 herein said groove or slit is cut into the back of said door frame during installation.
5. The assembly of claim 1 wherein said at least one shaped plate has sufficient length to spread impact loads along enough of the length of said door frame to prevent failure of said frame when impacts are applied to an associated door which is closed and latched to said frame.
6. The assembly of claim 1, further comprising sufficient mechanical fasteners to attach said shaped plate and said U-shaped bar to said door frame.
7. The assembly of claim 1 wherein the lengths of said shaped plate and said U-shaped bar are sufficient to spread the impact loads along enough of the length of said door frame to prevent said frame from failure when impacts are applied to an associated door which is closed and latched to said frame.
8. A reinforced door frame comprising two frame legs, a header and a sill, wherein the leg adjacent the lockset of a door to be installed therein comprises reinforcements for a strike plate of said lockset and a deadbolt throw bolt, said reinforcements comprising a) at least one shaped, generally flat plate adapted to be fastened to the back of said frame leg adjacent said lockset and/or deadbolt receptacles, said plate comprising at least one elongated hole extending parallel to the sides of the plate and door frame and adapted to permit positioning and installation using mechanical fasteners, a hole extending through said plate designed and adapted to accommodate said door latch and/or deadbolt when locked, with a support flange extending perpendicular to said plate adapted to fit into a portion of the opening for said door latch and/or deadbolt, and a portion of said plate extending substantially the full length of said plate and bent perpendicular to said plate to permit secure attachment to a groove or slit in said door frame; b) a U-shaped bar having a broad “U” shaped cross section and sufficient holes along the centerline of the length thereof to permit secure installation and fastening to a rectangular groove in the back of said frame, adapted to receive said U-shaped bar, wherein c) said shaped plate, in place of the perpendicular bend of a portion of a portion along its edge, comprises a double 90 degree bend forming a flat offset portion which extends below the plate itself and parallel thereto, being adapted to fit into said U-shaped bar, and fits the bottom surface thereof when said shaped pate is installed adjacent said U-shaped bar to reinforce said door frame adjacent said openings for said latch and/or deadbolt, wherein said shaped plate and said U-shaped bar are held in place by mechanical fasteners.
9. A pre-hung door assembly comprising the reinforced door frame of claim 8 and a door mounted on hinges thereto.
10. A method of installing at least one entry door frame reinforcing assembly in a door frame leg, comprising steps of: a) providing a door frame leg having a groove or slit in the back thereof, or cutting such a groove or slit into a frame leg during field installation; b) positioning a shaped, generally flat plate comprising at least one elongated hole extending parallel to the sides of the plate, which is adapted to permit the positioning and installation of said plate in contact with said frame leg using mechanical fasteners, and further has a hole extending through said plate, so that said plate contacts the back of said frame leg in a position where said hole can accommodate a door latch or deadbolt, and further c) ensuring that a support flange extending perpendicular to said plate is fitted into a portion of the opening for said door latch or deadbolt and a portion of said plate extending substantially the full length of said plate which is bent perpendicular to said plate to form a flange is inserted securely into said groove or slit, and thereafter d) securing said shaped plate in position using mechanical fasteners, and wherein (e) said portion of said plate bent perpendicular to said plate and extending substantially its full length has an additional 90 degree bend at its end, forming a flat offset portion having a bottom surface parallel to the door frame surface and adapted to fit into a groove in said frame leg which is provided or cut wide enough to accommodate the bent portion of said plate parallel to said plate surface.
11. The method of claim 10, further comprising steps of: a) installing a U-shaped bar having holes along the centerline thereof by positioning it in said groove and securing it therein with mechanical fasteners; b) inserting said flat offset portion of said shaped plate into said U-shaped plate; c) simultaneously placing said support flange into the opening for said door latch or said deadbolt; and d) securing said shaped plate in position using mechanical fasteners, wherein said offset portion of said shaped plate is adapted to fit inside said U-shaped bar.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will be better understood and aspects other than those set forth above will become apparent when consideration is given to the following detailed description, the appended claims and drawings. The same numerals are used to designate like components in these figures. Such description makes reference to the annexed drawing wherein:
(2) FIG. 1 is an oblique sectional view of the back of a door frame fitted with the described assembly.
(3) FIG. 2 is a cross section AA′ view of the door frame depicted in FIG. 1 with the described assembly attached.
(4) FIGS. 3A and 3B are, respectively, the face and cross-section AA′ views of the shaped plate component of the described assembly.
(5) FIGS. 4A and 4B are, respectively, the face and cross-section AA′ views of the U-shaped bar component of the described assembly.
(6) FIG. 5 is a plan view of the back of the door frame showing the location of the assembly in relation to the lock bore and throw bolt.
(7) FIG. 6 is an oblique sectional view of the back of a door frame fitted with only the shaped plate.
(8) FIG. 7 is an oblique sectional view of the back of a door frame fitted with an alternative version of the shaped plate only.
(9) FIG. 8 is an oblique sectional view of the back of a wider door frame fitted with the described assembly.
(10) FIG. 9 is a cross section AA′ view of the door frame depicted in FIG. 1 with the addition of a door edge and throw bolt extended in the locked position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
(11) In general, the following description adopts a terrestrial frame of reference, in which the bottom of a component is considered to be the side nearest the floor or earth when in normal use, and the top being the side opposite and facing upward. The term “face” is used to identify the portion of the door frame that is in closest proximity to the door and is visible after installation. The term “back” is used to identify the reverse portion of the door frame that is in closest proximity to the surrounding wall and its internal framing and is not visible after installation. The term “and/or” is used in the conventional sense, in which “A and/or B” indicates that A or B, or both, may be present.
(12) A variety of typical mechanical fasteners can be used to assemble the components of the system embodiments described below, including without limitation nails, staples of various types, machine screws and bolts, wood and sheet metal screws, dowels and pins of various sorts. Persons skilled in the art will be well prepared to use the mechanical fasteners provided with the assembly or to provide or substitute fasteners of their own choices.
(13) With reference to FIG. 1, the back of the door frame (10) is shown with the shaped slot (11) machined or extruded into it. Positioned where the lock/latch bore (16) is located on the door frame (10) and within the shaped slot (11) is a U-shaped bar (12). The U-shaped bar (12) is fitted with a series of attachment holes (13) that allow fasteners (20) to pass through the shaped bar (12) and secure it in position within the shaped slot (11) and the door frame (10). The width and depth of the shaped slot (11) are slightly greater than the width and depth of the U-shaped bar (12) so as to allow the U-shaped bar (12) to be fully contained within it. Shaped plate (14) is then aligned with the lock/latch bore (16) and set into place so that it lies flat on the back of the door frame (10) and the offset section (23) of the shaped plate (14) sets within the U-shaped bar (12) and shaped slot (11). The shaped plate (14) is then attached to the back of the door frame (10) by inserting and securing fasteners (not shown) through the attachment holes (18) in the offset section (23) of the shaped plate (14) which align with slotted holes (hidden in this view) in the U-shaped bar (12). Shaped plate (14) has a lock/latch opening (15) that surrounds the lock/latch bore (16) that is cut into the frame (10) to allow for the throw bolt of the deadbolt or latch of the lockset (not shown) to pass through the frame (10). The edge of the lock/latch opening (15) in shaped plate (14) has a support flange (19) which extends into the lock/latch bore (16). The length of the support flange (19) is such that it does not extend fully through the lock/latch bore (16) so as not to interfere with the mounting of the decorative lock or latch cover (not shown). The support flange (19) is of a width and location so that it fits within the lock/latch bore (16) but still allows sufficient clearance for the latch or throw bolt (not shown) to be extended into and through the lock/latch bore (16). The support flange (19) helps to secure shaped plate (14) to door frame (10) and to support a longer length of the latch or throw bolt within bore (16). The shaped plate (14) also features two slotted holes (17) which are positioned so that, during installation, long fasteners (not shown) can be driven or screwed through the face of the door frame (10) adjacent to the weatherstrip slot (21), pass through the shaped plate (14) and penetrate and be secured to the framing within the wall that surrounds the entry. The location of the slotted holes (17) is such that the heads of the fasteners will be hidden from view when the weatherstrip (not shown) is installed into the weatherstrip slot (21) machined into the face of the door frame (10).
(14) With reference to FIG. 2, the door frame (10) cross section is shown with the shaped slot (11) machined or extruded into it. Positioned where the lock/latch bore (16) is located on the door frame (10) and within the shaped slot (11) is the U-shaped bar (12). The width and depth of the shaped slot (11) are slightly greater than the outer width and depth of the U-shaped bar (12) so as to allow the U-shaped bar (12) to be fully contained within it. The shaped plate (14) is then aligned with the lock/latch bore (16) and set into place so that it lies flat on the back of the door frame (10) and the offset section (23) of the shaped plate (14) drops within the U-shaped bar (12) and shaped slot (11). The offset section (23) of the shaped plate (14) is then attached to the back of the door frame (10) by inserting and securing fasteners (20) through the holes (18) in the offset section (23) of the shaped plate (14) which align with slotted holes (22) in the U-shaped bar (12). The shaped plate (14) has a lock/latch opening (15) that surrounds the lock/latch bore (16) that is cut into the door frame (10) to allow for the throw bolt and/or latch (not shown) to pass through the door frame (10). The edge of the lock/latch opening (15) includes a support flange (19) which extends into the lock/latch bore (16). The support flange (19) is of a width, thickness and location such that it fits within the lock/latch bore (16) but still allows sufficient clearance for the latch or throw bolt (not shown) to be extended into and through the lock/latch bore (16). The length of the support flange (19) is such that it does not extend fully through the lock/latch bore (16). The shaped plate (14) also features slotted holes (17) which are positioned so that, during installation, long fasteners (not shown) can be driven though the face of the door frame (10) next to the weatherstrip slot (21), pass through the shaped plate (14) and penetrate and be secured to the wall that surrounds the entry. The locations of the slotted holes (17) are such that the heads of the fasteners (not shown) are located next to the weatherstrip slot (21) so that when the weatherstrip (not shown) is installed the heads of the fasteners (not shown) will be hidden from view.
(15) With reference to FIGS. 3A and 3B, the shaped plate (14) is shown with the lock/latch opening (15) and support flange (19) that are to, respectively, surround and fit within the lock/latch bore (not shown) of the door frame (not shown). The shaped plate (14) features a plate offset (25) that creates an offset section (23) that will fit within the U-shaped bar (not shown). The offset section (23) has a series of attachment holes (18) where fasteners (not shown) will be inserted to secure the offset section (23) of the shaped plate (14) within the U-shaped bar (not shown) and to the back of the door frame (not shown). The shaped plate (14) also features a pair of slotted holes (17) that allow for long fasteners (not shown) to pass through the shaped plate (14) as they are driven into the face of the door frame (not shown) and into the framing that surrounds the door entry. Shaped plate's (14) flange (19) and offset section (23) can be formed in metal by simple cutting and bending operations or can be produced by molding and/or machining of composite materials.
(16) With reference to FIGS. 4A and 4B, the U-shaped bar (12) is shown with a number of attachment holes (13) and slotted holes (22) located down the centerline so that the U-shaped bar (12) can be inserted into the shaped slot (not shown) with either end oriented to the top of the door frame (not shown). When the U-shaped bar (12) has been inserted into the correct location in the shaped slot (not shown) in the back of the door frame (not shown), a series of fasteners (not shown) will be inserted through the attachment holes (13) so as to secure the shaped bar (12) firmly to the back of the door. frame (not shown). The shaped plate (14) (not shown) is then positioned within the U-shaped bar (12) and fasteners (not shown) are inserted through the attachment holes in the offset section of the shaped plate (not shown here; see FIGS. 3A/3B.) and through the slotted holes (22) and secured to the door frame (not shown) so as to hold the shaped plate (14) (not shown) securely within the U-shaped bar (12).
(17) With reference to FIG. 5, the previously described back of the door frame (10) is shown fitted with both the U-shaped bar (12) and shaped plate (14) and with the location of the throw bolt (24) relative to these pieces shown. The U-shaped bar (12) is secured in place using fasteners (not shown) which pass through the series of attachment holes (not shown) and into the back of the door frame (10). The shaped plate (14) is secured in place using fasteners (not shown) that pass through both the attachment holes (18) and the slotted holes (22) located in the offset section (23) of the shaped plate (14) and into the back of the door frame (10). The lock/latch opening (15) surrounds the lock/latch bore (16) and the support flange (19) fits into the lock/latch bore (16). The shape, size and location of the support flange (19) is such that the throw bolt (24) of the door deadbolt has clearance and will extend through the door frame (10) without interference. The previously described slotted holes (17) in the shaped plate (14) are also shown.
(18) With reference to FIG. 6, the previously described door frame (10) is shown fitted with only the shaped plate (14) within shaped slot (11), without the need of a U-shaped bar. The shaped plate (14) is secured within the shaped slot (11) using fasteners (not shown) that pass through the attachment holes (18) located in the offset section (23) of the shaped plate (14) and into the back of the door frame (10). The lock/latch opening (15) surrounds the lock/latch bore (16) and the support flange (19) fits into the lock/latch bore (16). The previously described slotted holes (17) in the shaped plate (14) are also shown.
(19) With reference to FIG. 7, the previously described door frame (10) is shown fitted with only the modified shaped plate (14). The shaped plate (14) is simply secured within a shaped slot (11), of reduced width, using fasteners (not shown) that pass through the attachment holes (18), that have been moved to an alternate location in the plate (14), and into the back of the door frame (10). The lock/latch opening (15) surrounds the lock/latch bore (16) and the support flange (19) fits into the lock/latch bore (16). The previously described slotted holes (17) in the shaped plate (14) are also shown.
(20) With reference to FIG. 8, a wider version of the previously described door frame (10) is shown fitted with shaped slot (11) machined or extruded into it. The shaped slot (11) is located the same distance from the thin edge of the door frame (10), so as a result the same size U-shaped bar (12) and shaped plate (14) can be used to reinforce this wider frame without modification. Positioned where the lock/latch bore (16) is located on the door frame (10) and within the shaped slot (11) is a U-shaped bar (12). The U-shaped bar (12) is fitted with a series of attachment holes (13) that allow fasteners (20) to pass through the U-shaped bar (12) and secure it in position within the shaped slot (11) and the door frame (10). The width and depth of the shaped slot (11) are slightly greater than the width and depth of the U-shaped bar (12) so as to allow the U-shaped bar (12) to be fully contained within it. Shaped plate (14) is then aligned with the lock/latch bore (16) and set into place so that it lies flat on the back of the door frame (10) and the offset section (23) of the shaped plate (14) sets within the U-shaped bar (12) and shaped slot (11). The shaped plate (14) is then attached to the back of the door frame (10) by inserting and securing fasteners (not shown) through the attachment holes (18) in the offset section (23) of the shaped plate (14) which align with slotted holes (hidden in this view) in the U-shaped bar (12). Shaped plate (14) has a lock/latch opening (15) that surrounds the lock/latch bore (16) that is cut into the frame (10) to allow for the throw bolt of the deadbolt or latch of the lockset (not shown) to pass through the frame (10). The edge of the lock/latch opening (15) has a support flange (19) which extends into the lock/latch bore (16). The length of the support flange (19) is such that it does not extend fully through the lock/latch bore (16) so as not to interfere with the mounting of the decorative lock or latch cover (not shown). The support flange (19) is of a width and location so that it fits within the lock/latch bore (16) but still allows sufficient clearance for the latch or throw bolt (not shown) to be extended into and through the lock/latch bore (16). The shaped plate (14) also features two slotted holes (17) which are positioned so that, during installation, long fasteners (not shown) can be driven or screwed through the face of the door frame (10) adjacent to the weatherstrip slot (21), pass through the shaped plate (14) and penetrate and be secured to the framing within the wall that surrounds the entry. The location of the slotted holes (17) is such that the heads of the fasteners will be hidden from view when the weatherstrip (not shown) is installed into the weatherstrip slot (21) machined into the face of the door frame (10).
(21) With reference to FIG. 9, the door frame (10) cross section is shown with the shaped slot (11) machined or extruded into it. Positioned where the lock/latch bore (16) is located on the door frame (10) and within the shaped slot (11) is the U-shaped bar (12). The width and depth of the shaped slot (11) are slightly greater than the outer width and depth of the U-shaped bar (12) so as to allow the U-shaped bar (12) to be fully contained within it. The shaped plate (14) is then aligned with the lock/latch bore (16) and set into place so that it lies flat on the back of the door frame (10) and the offset section (23) of the shaped plate (14) drops within the U-shaped bar (12) and shaped slot (11). The offset section (23) of the shaped plate (14) is then attached to the back of the door frame (10) by inserting and securing fasteners (20) through the holes (18) in the offset section (23) of the shaped plate (14) which align with slotted holes (22) in the U-shaped bar (12). The shaped plate (14) has a lock/latch opening (15) that surrounds the lock/latch bore (16) that is cut into the door frame (10) to allow for the throw bolt (24) of the deadbolt (not shown) to be extended from the edge of the door (26) and pass through the door frame (10) when the deadbolt (not shown) is locked. The edge of the lock/latch opening (15) includes a support flange (19) which extends into the lock/latch bore (16). The support flange (19) is of a width, thickness and location such that it fits within the lock/latch bore (16) but still allows sufficient clearance for the latch or throw bolt (24) to be extended into and through the lock/latch bore (16). The length of the support flange (19) is such that it does not extend fully through the lock/latch bore (16). The shaped plate (14) also features slotted holes (17) which are positioned so that, during installation, long fasteners (not shown) can be driven though the face of the door frame (10) next to the weatherstrip slot (21), pass through the shaped plate (14) and penetrate and be secured to the wall that surrounds the entry. The location of the slotted holes (17) is such that the heads of the fasteners (not shown) are located next to the weatherstrip slot (21) so that when the weatherstrip (not shown) is installed the heads of the fasteners (not shown) will be hidden from view.
(22) The operation of certain disclosed embodiments will be further illustrated by the following examples:
EXAMPLES
(23) Example 1—A U-shaped bar and shaped plate were fabricated by cutting and bending 16-gage galvanized sheet steel (ASTM A653 CS Type B) into the shapes depicted in FIGS. 3 and 4. The dimensions of the U-shaped bar were 0.875″×0.300″×15.75″. The dimensions of the shaped plate were 3.600″×3.500″×0.300″ (at the offset). A strike side door frame was prepared from pine lumber with a correctly sized shaped slot machined into the back of the door frame and latch/deadbolt holes and mortises were machined into the door frame. The U-shaped bar and one shaped plate were installed, as described previously in the detailed description, onto the back of the strike frame leg with the shaped plate located at the deadbolt. A hinge side door frame was prepared from pine lumber and three hinge mortises were machined into it. A door frame header was prepared from pine lumber and cut to the required length. A commercially available residential door sill was procured and trimmed to the correct length. A solid wood door (36″×78″×1¾″) was prepared by machining bores and mortises for the lock and deadbolt and for three hinges. The door frame legs, door frame head and sill were assembled using 3″ construction screws into a door frame and the door was mounted to the frame using three commercially available hinges. A commercially available ANSI 1 level lockset was installed in the door. Decorative latch and deadbolt cover plates (light duty) were mounted into the mortises of the strike jamb. The door and frame set were then mounted into the test fixture prescribed in ASTM F476-14. The door was closed and both the latch and deadbolt were locked. The door was then subjected to the door impact test protocol described in section 17 of ASTM F476-14 by an independent test lab. The door assembly successfully endured all levels of impact up to and including the highest Grade 40 level (two impacts each of 80, 120 160 and 200 Joules or 59.0, 88.5, 118.0 and 147.5 ft-lbf). The strike jamb showed no cracking or other damage as a result of the testing.
(24) Example 2—A U-shaped bar and shaped plate were fabricated by cutting and bending 16-gage galvanized sheet steel (ASTM A653 CS Type B) into the shapes depicted in FIGS. 3 and 4. The dimensions of the U-shaped bar were 0.875″×0.300″×15.75″. The dimensions of the shaped plate were 3.600″×3.500″×0.300″ (at the offset). A strike side door frame was prepared from pine lumber with a correctly sized shaped slot machined into the back of the door frame and latch/deadbolt holes and mortises were machined into it. The U-shaped bar and one shaped plate were installed, as described previously in the detailed description, onto the back of the strike frame leg with the shaped plate located at the deadbolt. A hinge side door frame was prepared from pine lumber and three hinge mortises were machined into it. A door frame header was prepared from pine lumber and cut to the required length. A commercially available residential door sill was procured and trimmed to the correct length. A solid wood door (36″×78″×1¾″) was prepared by machining bores and mortises for the lock and deadbolt and for three hinges. The door frame legs, door frame head and sill were assembled using 3″ construction screws into a door frame and the door was mounted to the frame using three commercially available hinges. A commercially available ANSI 3 level lockset was installed in the door. Decorative latch and deadbolt cover plates (light duty) were mounted into the mortises of the strike jamb. The door and frame set were then mounted into the test fixture prescribed in ASTM F476-14. The door was closed and both the latch and deadbolt were locked. The door was then subjected to the door impact test protocol described in section 17 of ASTM F476-14 by an independent test lab. The door assembly successfully endured the first two levels of impact (Grade 10 and 20) and had a failure of the ANSI 3 deadbolt at the start of the Grade 30 level of testing (two impacts each of 80 and 120 Joules, failing at first impact of 160 Joules).
(25) Published testing by Kikgard, another commercially available door reinforcement product, showed that a typical softwood door frame without reinforcement will break and allow the door to be forced open at the lowest impact level (80 Joules) so that it will fail to achieve even the lowest Grade 10 performance level. With the addition of the U-shaped bar and the shaped plate describe above, the ability of the pine door frame to resist the impact of forced entry was significantly improved so that the maximum amount of impact that the door can be subjected to without failure was determined by the strength of the lockset used, as the reinforced frame did not fail in testing.
(26) In the foregoing description, certain terms have been used for brevity, clarity and understanding. All equivalent relationships to those illustrated in the drawings and described in the preferred embodiment are to be encompassed by this present invention to produce the intended results. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
