DOOR HANGER BRACKET

Abstract

A door assembly, a hanger bracket therefor which comprises an elongated manually bendable body which extends from a first wall mounting tab at one end, for a distance approximately equal to the width of a doorjamb, and sufficiently far beyond to provide for forming a second wall mounting tab. The elongated body includes at least one bend line extending laterally with respect to the length of said body, whereby the body can be manually bent to form said second wall mounting tab, after the bracket has been secured to the jamb of the door assembly and the door assembly located in the door opening of the wall and secured to one side of the wall by the first wall mounting tab. Two bend lines are shown such that the bracket can be used in a wall having drywall on both sides, or in a wall having drywall on only one side.

Claims

1. A door hanger bracket comprising: an elongated manually bendable body; a pre-formed first wall mounting tab projecting laterally from a first end of said body; said elongated manually bendable body extending from said first wall mounting tab for a distance approximately equal to the width of a door jamb, and sufficiently far beyond to provide for forming a second wall mounting tab; said elongated manually bendable body including at least one bend line extending laterally with respect to the length of said elongated manually bendable body, whereby said manually bendable body can be manually bent at said bend line to form said second wall mounting tab projecting laterally from said elongated manually formable body at said bend line.

2. The door hanger bracket of claim 1 in which said at least one bend line comprises first and second bend lines spaced from one another along the length of said elongated manually bendable body; said first bend line being located at a distance from said first wall mounting tab which is approximately equal to the width of a finished wall having dry wall on both sides of said wall; said second bend line being located at a distance from said first wall mounting tab which is approximately equal to the width of a wall having dry wall on only one side of said wall, whereby said second wall mounting tab can be formed by bending said elongated manually bendable body at either said first bend line or said second bend line.

3. The door hanger bracket of claim 2 in which each said first and second bend lines comprise an elongated narrow notch in said elongated manually bendable body.

4. The door hanger bracket of claim 3 in which said elongated manually bendable body has a lateral width with side edges circumscribing said lateral width; each said elongated narrow notch extending only partially across said lateral width of said elongated manually bendable body, stopping short of said side edges of said elongated manually bendable body.

5. The door hanger bracket of claim 4 in which each said elongated narrow notch partially penetrates the surface of said elongated manually bendable body.

6. The door hanger bracket of claim 5 in which said elongated manually bendable body having a jamb facing surface which will face a door jamb when said bracket is secured to said doorjamb, and a wall facing surface which will face the wall when an assembled door hanger bracket and said door jamb are positioned in a wall opening; said elongated narrow notch penetrating said jamb facing surface of said elongated manually bendable body.

7. The door hanger bracket of claim 6 in which said elongated manually bendable body is formed of a manually bendable metal; each said bend line being stamped into said jamb facing surface of said elongated manually bendable body to form each said elongated narrow notch; each said elongated narrow notch projecting slightly from said wall facing surface of said elongated manually bendable body, whereby when one is bending said elongated manually bendable body to form said second wall mounting tab, one is bending in the same direction into which said elongated narrow notch projects.

8. The door hanger bracket of claim 7 in which door jamb mounting holes are positioned offset from but near the ends of each said bend line, whereby upon manual bending said elongated manually bendable body at either of said bend lines, in-situ gussets are formed above and below said elongated narrow notch.

9. The door hanger bracket of claim 2 in which at least one bracket positioning tab is formed at said first end of said elongated manually bendable body, essentially parallel to and projecting in the opposite direction from said first wall mounting tab to enhance the alignment and positioning of said bracket on said doorjamb.

10. The door hanger bracket of claim 2 in which said door hanger bracket is made of manually bendable metal, and at least one preformed gusset is impressed into said first wall mounting tab so as to project into the inside corner of the junction between first wall mounting tab and elongated manually bendable body; said gusset extending from said inside corner into said wall mounting tab to a distance which is just sufficient to leave a space when said bracket and assembled jamb are positioned in a wall opening, between the exposed end of a wall and the face of the jamb, so as to accommodate the heads of screws used to mount said bracket on a jamb.

11. The door hanger bracket of claim 10 in which said gusset extends from said inside corner a distance of from to of an inch; said gusset extend inwardly into said tab to a depth of from 1/16 to of an inch.

12. The door hanger bracket of claim 11 in which there are two said gussets in said first wall mounting tab.

13. The door hanger bracket of claim 1 in which said elongated manually bendable body is formed of a manually bendable metal; said elongated manually bendable body having a jamb facing surface which will face a door jamb when said bracket is secured to a said doorjamb, and a wall facing surface which will face the wall when an assembled door hanger bracket and said door jamb are positioned in a wall opening; each said bend line being stamped into said jamb facing surface of elongated manually bendable body to form said elongated narrow notch; each said elongated narrow notch projecting slightly from said wall facing surface of said elongated manually bendable body, whereby when one is bending said elongated manually bendable body to form said second wall mounting tab, one is bending in the same direction into which said elongated narrow notch projects.

14. The combination of a plurality of door hanger brackets attached to a pre-hung door assembly comprising a jamb, a door, and hinges joining said door to said jamb; each of said door hanger brackets being the bracket of claim 1.

15. The combination of claim 14 in which each of said door hanger brackets is the bracket of claim 2.

16. The combination of claim 14 in which each of said door hanger brackets is the bracket of claim 13.

17. A method for securing a pre-hung door having a door, a jamb having first and second spaced sides and a top cross piece, and hinges securing said door to said first side of said jamb, said method comprising: securing a plurality of door hanger brackets to said hinged first side jamb of said pre-hung door assembly; each said door hanger bracket comprising: an elongated manually bendable body; a first wall mounting tab projecting laterally from a first end of said body; said elongated manually formable body extending from said first wall mounting tab for a distance approximately equal to the width of a door jamb, and sufficiently far beyond to provide for forming a second wall mounting tab; said elongated manually bendable body including at least one bend line extending laterally with respect to the length of said elongated manually bendable body, whereby said manually bendable body can be manually bent at said bend line to form said second wall mounting tab projecting laterally from said elongated manually formable body at said bend line. positioning said pre-hung door assembly with said secured hanger brackets in a door opening of a wall having first and second sides, with said first wall mounting tabs adjacent said first wall side; securing said first wall mounting tabs of said brackets to their adjacent first wall side; bending said elongated manually bendable body of each said bracket at said bend line to form said second wall mounting tabs adjacent said second wall side; securing said second wall mounting tabs to said second wall side.

18. The method of claim 17 which includes using wall mounting brackets in which said at least one bend line comprises first and second bend lines spaced from one another along the length of said elongated manually bendable body; said first bend line being located at a distance from said first wall mounting tab which is approximately equal to the width of a finished wall having dry wall on both sides of said wall; said second bend line being located at a distance from said first wall mounting tab which is approximately equal to the width of a wall having dry wall on only one side of said wall; said step of bending including bending said elongated body at either said first or said second bend line, depending on the thickness of said wall.

19. The method of claim 18 in which said brackets used are formed of a manually bendable metal; said elongated manually bendable body having a jamb facing surface which will face a door jamb when said bracket is secured to said doorjamb, and a wall facing surface which will face the wall when an assembled door hanger bracket and said door jamb are positioned in a wall opening; each said bend line being stamped into said jamb facing surface of elongated manually bendable body to form said elongated narrow notch; each said elongated narrow notch projecting slightly from said wall facing surface of said elongated manually bendable body, whereby when one is bending said elongated manually bendable body to form said second wall mounting tab, one is bending in the same direction into which said elongated narrow notch projects.

20. (canceled)

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23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. (canceled)

28. The door hanger bracket of claim 4 with said elongated manually bendable body having a jamb facing surface which will face a door jamb when said bracket is secured to a door jamb, and a wall facing surface which will face the wall when an assembled door hanger bracket and jamb are positioned in a wall opening; said elongated narrow notch penetrating the surface of said jamb facing surface of said elongated manually bendable body.

29. The door hanger bracket of claim 28 in which said bracket is formed of a manually bendable metal; each said bend line being stamped into said jamb facing surface of elongated manually bendable body to form said elongated narrow notch; said elongated narrow notch projecting slightly from said wall facing side of elongated body, whereby when one is bending elongated body to form said second wall mounting tab, one is bending in the same direction into which said notch projects.

30. (canceled)

31. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The preferred embodiments of the invention will now be described with respect to the drawings, in which:

[0019] FIG. 1 is an inside perspective view of a preferred embodiment bracket;

[0020] FIG. 2 is an outside perspective view of the preferred embodiment bracket;

[0021] FIG. 3 is a fragmentary side elevation of the doorjamb with the bracket secured to the door jamb, where the door will be mounted to a wall having drywall mounted on both inside and outside wall surfaces;

[0022] FIG. 4 is a fragmentary side elevation of the doorjamb with the bracket secured to the door jamb, where the door will be mounted to a wall having drywall mounted on only one of the wall surfaces;

[0023] FIG. 5 is a perspective view of the bracket secured to the doorjamb;

[0024] FIG. 6 is a front elevation of the door jamb positioned in the door opening, with three brackets on the hinge side and three brackets on the opening side, with all brackets attached to the wall;

[0025] FIG. 6A shows the enlarged area VIA of FIG. 6;

[0026] FIG. 7 is a rear elevation of the doorjamb positioned in the door opening, with two of the brackets bent and secured to the wall, and the remaining four brackets yet to be bent;

[0027] FIG. 8 is the cross section VIII-VIII of FIG. 6 showing the front side of the bracket attached to the wall, and the tail side of the bracket unbent;

[0028] FIG. 8A is the enlarged area of FIG. 8;

[0029] FIG. 9 is the cross section of FIG. 8 showing the front side of the bracket attached to the wall, and the tail side of the bracket bent and attached to the wall, with drywall on both sides;

[0030] FIG. 9A is the enlarged area of FIG. 9;

[0031] FIG. 10 is the cross section VII-VII of FIG. 6 showing the front side of the bracket attached to the wall, and the tail side of the bracket unbent, with an unfinished wall on the back side;

[0032] FIG. 11 is the cross section of FIG. 10 showing the front side of the bracket attached to the wall, and the tail side of the bracket bent and attached to the wall, with an unfinished wall on the back side;

[0033] FIG. 12 shows an inside perspective view of an alternative one side mount bracket; and

[0034] FIG. 13 shows the outside perspective view of the alternative bracket of FIG. 12.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

General Description

[0035] In the preferred embodiments, the door hanger bracket 20 comprises an elongated manually bendable body 200 with a first wall mounting tab 201 at one end, projecting laterally from said body (FIGS. 1 and 2). Elongated body 200 extends from said first wall mounting tab 201 for a distance approximately equal to the width of a doorjamb, and sufficiently far beyond to provide for forming a second wall mounting tab 230. Thus, elongated body 200 includes a main body portion 210 and a wall mounting tab portion 230. Body 200 includes at least one bend line 212 extending laterally with respect to the length of said body 200, whereby said body 200 can be manually bent to form said second wall mounting tab 230a (Compare FIGS. 8 and 9).

[0036] Preferably, there are two said bend lines 212 and 213 spaced from one another along the length of said body 200. The first bend line 212 is located at a distance from said first wall mounting tab 201 which is approximately equal to the width of a finished wall 40 having dry wall 42 and 42a on both sides of said wall 40 (FIGS. 8 and 9). The second bend line 213 is located at a distance from said first wall mounting tab 201 which is approximately equal to the width of a wall 40a having dry wall 42 on only one side of said wall (FIGS. 10 and 11).

[0037] In use with a door assembly 10 having a door jamb 50 and a hinged door 30, several brackets 20 are secured to jamb 50 with said first wall mounting tab 201 aligned with the edge of said jamb 50 with the help of positioning and alignment tabs 203, and with said manually formable elongated body 200 extending beyond the opposite edge of said jamb 50 (FIGS. 5, 3 and 4). The jamb and bracket assembly is then positioned in an opening in wall 40 (FIGS. 6 and 7). Wall 40 may be a finished wall as shown in phantom in FIG. 3, having dry wall 42 and 42a on both sides (FIGS. 8 and 9). Alternatively, it may be a narrower wall 40a as shown in phantom in FIG. 4, having drywall on only one side, and perhaps nothing or only a thin covering on the other side (FIGS. 10 and 11). If it is a wall 40 having dry wall on both sides, the extending portion 230 of elongated body 200 is manually bent at first bend line 212, to form a second wall mounting tab 230a. Tab 230a is then secured to wall 40 through the drywall 42a (FIGS. 8 and 9). If it is a wall 40a having drywall on only one side, the extending portion 230a is bent at second bend line 213, to form a longer second wall mounting tab 230b. Tab 230b is then secured to the wall stud 41 (FIGS. 10 and 11).

[0038] Preferably, brackets 20 are made of a bendable metal such as steel, galvanized steel, aluminum or other reasonable materials. The thickness of the bracket material depends on the strength of the material selected, and the amount of security required for the finished door assembly installation. A range of thickness from 0.020-0.125 inches can be used for most bendable materials. A preferred metal is a galvanized and heat treated steel, commonly known as Galvaneal, with a thickness of about 0.030 inches. Preferably, the metal is formed into manually formable bracket 20 by stamping.

Terminology and Parts

[0039] The terms lateral as used herein means generally perpendicular to. Similarly the term perpendicular as used herein means generally perpendicular, or essentially perpendicular. The term approximately equal is used to allow for limited variation from precise equality which is not sufficient to interfered with the intended functionality of the approximately equal components or features of door hanger bracket 20. The components discussed herein are numbered as shown below: [0040] 10Door Assembly [0041] 11Plumb Line [0042] 20Door Hanger Bracket [0043] 30Door [0044] 31Door Hinge [0045] 32Door Latch [0046] 40Wallstandard thickness [0047] 40aWallnarrower thickness [0048] 41Wall Stud [0049] 42First side Wall Surfacing Material (drywall) [0050] 42asecond side Wall Surfacing Material (drywall) [0051] 44Wall mounting screw [0052] 50Door Jamb [0053] 60Rough Wall Opening [0054] 20Door Hanger Bracket [0055] 200Manually bendable elongated body [0056] 201Preformed first wall mounting Tab [0057] 202Preformed corner [0058] 203Preformed bracket positioning tab(s) [0059] 204Preformed gussets [0060] 205First wall mounting slot [0061] 206wall alignment marks [0062] 207Hinge Screw Compensation Hole [0063] 210Main portion of elongated body 200 [0064] 211Doorjamb mounting holes [0065] 212Preformed bend line/notch(s) [0066] 213Second preformed bend line/notch [0067] 214Jamb mounting screw [0068] 230Second wall mounting tab forming portion of elongated body 200 [0069] 230amanually bent second wall mounting tab for a full width wall [0070] 230bmanually bent second wall mounting tab for narrow wall [0071] 231second wall mounting slot [0072] 234in-situ gusset [0073] 25Single wall door hanger bracket [0074] 210atriangular jamb mounting body

Bend Lines

[0075] The bend line features 212 and 213 can be formed as narrow slots, grooves, or a series of drilled holes though it is most preferable to stamp the bend lines into metal main body 200 to form elongated narrow notches, which might also be described as grooves (FIGS. 1 and 2). The elongated narrow notch partially penetrates the surface of the metal on the jamb wall facing surface of said main body, and the metal to either side of the penetrating portion of the notch slopes downwardly slightly to the penetrating portion. Preferably, the notches 212/213 are stamped into the jamb mounting side of main body 200, to project slightly from the surface of the wall facing side of main body 200. Accordingly, one is bending main body 200 in the same direction which the notch 212 or 213 projects. One would think that the notches 212 and 213 should be made in the wall facing side of main body 200, to provide bend relief on the inside corner of the manual bend which forms said second wall mounting tab 230. We have found surprisingly, that by forming bend lines 212 and 213 to project into the inside corner to be formed, the bending of main body 200 is easier and forms a sharper, tighter radius bend at the corner of formed tab 230 and main body 200.

[0076] Also, preferably, bend lines 212 and 213 extend only partially across the lateral width of main body 200, stopping short of the side edges of main body 200. Further, it has been discovered by locating the door jamb mounting holes 211 and the heads of the jamb mounting screws 214 near the bend line notch 212/213 provides a stress relief pattern extending from each end of the bend line, which upon manual bending forms an in-situ gusset 234 above and below the bend line (FIG. 9A). This improves the stability of the second wall mounting tab 230 when bent and attached to the wall.

[0077] Typically, on a bracket with a width of 1.5-2.0 inches the optimum bend line notch has a length of to inches, with length of inch most preferred. In accordance with this notch size, the jamb mounting holes 211, which are typically 1/16 to inch in diameter with 3/16 diameter preferred, would be set inward towards the first wall mount tab 201 from the bend line notch placement about 1/16 to inch, then approximately - inch outside of the end of the bend line notch 212 and at least inch inside the outer edge of the jamb mounting portion of the bracket 210.

Pre-formed Wall Mounting Tab

[0078] At least one smaller bracket positioning tab(s) 203 is formed at the first wall mounting tab 201 end of main body 200 essentially parallel to and projecting in the opposite direction from said first wall mounting tab to enhance the alignment and positioning of said bracket to said door jamb (FIG. 2). Preferably, one of said tabs 203 is located above and one below said first wall mounting tab 201.

[0079] Preferably at least one, preferably two preformed gussets 204 are impressed into said first wall mounting tab 201 to project into the inside corner of the junction between first wall mounting tab 201 and main body 200. Said gussets 204 extend from said inside corner into said wall mounting tab 201 to a distance which is just sufficient to leave a space 45 between the end of the wall 40 and face of jamb 50, which will accommodate the heads of the jamb mounting screws 214 (FIG. 8A). Typically, this distance is to of an inch, and preferably of an inch. The gussets are impressed inwardly into said tab 201 to a depth of 1/16- of an inch, with a depth of approximately .sup.th inch most preferred. The width of the gusset 204 is typically to of an inch at their widest point, depending on the thickness of the metal used and the spacing of the gussets. It is understood that the number, size, and specific location of the pre-formed gusset design can be reasonably altered to accommodate specialized bracket designs depending on the strength and thickness of the bracket material being used, as well as accommodations required for unique door assembly requirements.

[0080] In addition to improving the strength and quality of the finished door assembly, said gussets also make the packaged brackets stronger and more durable during normal shipping and handling associated with transportation and construction site applications which tend to bend or straighten many preformed features.

Jamb Mounting Body Design

[0081] The thickness and width of the door hanger bracket 20 can be adjusted in a variety of manners to adjust for the specific door assembly to be installed. The dimensions provided above typical for those used with a standard interior door assembly installation. It has been determined for this standard inside door application that several irregular shape profiles can be used on the jamb mounting portion of the bracket to optimize manufacturing efficiencies without compromising the strength and integrity of bracket 20. In the preferred embodiment, jamb mounting portion 210 of main body 200 is shaped in a bow tie fashion to provide sufficient strength at both the first wall tab 201 and the manually formed second wall tab 230, while tapering down in the middle portion of main body to minimize material utilization. The bow tie shape also facilitates stamping multiple brackets out of a sheet of metal in nesting fashion optimizing material utilization.

Door Assembly Installation Process

[0082] Turning to the drawings, a standard indoor door assembly 10 (shown in FIG. 6) is installed in a rough door opening 60 of the wall 40. A plumb line 11 is scribed on the hinge side 42 of first wall side 40 adjacent to the intended hinge 31 side of the doorjamb 50. Plumb line 11 extends from above the desired location of the top bracket 20 and continuing to below the desired location of the bottom door mounting bracket 20. The plumb line 11 is typically located on wall 40 approximately -1 inch away from the edge of the rough door opening 60 such that the preformed wall mounting tab 201 will cover a portion of the plumb line 11 during the installation of the door assembly. The proximity of the plumb line 11 to the preformed wall mounting tab 201 is then such that at least one of the wall alignment marks 206 overlays the plumb line and provides the means for the installer to have a ready reference for properly leveling the door assembly during installation.

[0083] Upon locating the hinge side of door assembly, the installer can locate the bracket 20 on the hinge 31 side of the doorjamb 50 with the first wall tab 201 located on the first wall 40 side of the opening with said tab extending away from the door jamb. Using the preformed bracket positioning tabs 203 the bracket location can be easily set such that the bracket is quickly located in close proximity to the door hinge 31 and essentially perpendicular with the hinge side doorjamb which provides for minimal tab protrusion challenges during final trim assembly. If additional security is desired for the finished door assembly, the bracket 20 can be aligned with the hinge 31 such that one of the hinge screws aligns with the hinge screw compensation hole 207 on the bracket. This allows for the subsequent installation of an extra-long screw to be driven thru the jamb 40 and bracket 20 into the stud wall 41.

[0084] At this point the installer can drive in 2 or more, and preferably 4 jamb mounting screws 214 thru the jamb mounting holes 211 in the bracket and into the doorjamb 50. The same process is completed for a second bracket 20 in close proximity to the remaining hinge 31 of the door assembly. If added security or strength is needed additional brackets may be added to the door flange at this time, with spacing of additional brackets determined to provide the best stress distribution possible.

Alternative Gusseted Embodiment

[0085] FIGS. 12 and 13 disclose an alternative embodiment door hanger bracket 25 having a main body which comprises only a triangular shaped jamb mounting portion 210a and a laterally projecting gusseted wall mounting tab 201 as described above. Jam mounting main body 210a includes jamb mounting holes 211 and a hinge screw compensation hole 207. It also includes positioning and alignment tabs 203 projecting laterally from the same edge as wall mounting tab 201 projects, but in the opposite direction and on either side thereof as described above.

[0086] Wall mounting tab 201 includes two gussets 204 as described above alignment notches 206 and wall mounting slot 205 as described above. This embodiment does not include a manually formable second wall mounting tab.

CONCLUSION

[0087] It is understood that several bracket widths and material variations can be selected depending upon the door assembly requirements involved. These may require adjustments to the dimensional layout provided above, and the basis of this example is provided for a preferred bracket design for a standard interior door installation with standard material sizes involved.

[0088] It is further understood that the number and spacing of the bend lines may vary for custom or non-standard door assembly designs and the specific example provided should not be considered limiting to this invention. For example, it may be desirable to have 3 or 4 bend lines established for customized door assemblies used in specialized clean room operations where standard -inch drywall is not commonly used and specialized fiberglass or plastic wall coverings, and other various combinations can create a wider variety of finished wall thickness requirements which would benefit from adding additional bend line features.

[0089] Of course, it is understood that this is a preferred embodiment, and that various changes and alterations can be made without departing from the spirit and scope of the invention as set forth in the appended claims.