COMPACT POCKET DOOR FRAME ASSEMBLY

Abstract

An improved compact pocket door frame for a sliding door. The frame employs a header support having an overhead track attached by T-nuts. A pair of vertical spreaders form a pocket recess entrance. A header spacer is positioned perpendicular to a lower surface of the header support and extends outwardly from the pocket recess. A header frame member is positioned perpendicular to each header spacer and extends outwardly from the pocket recess. The pocket door frame is constructed and arranged to provide dimensional stability and prevent warping or twisting. The header support is removably fastened to the vertical spreaders for shipping and storage whereby the header support is secured to the vertical spreaders forming a T-shape structure for wall mounting to support a sliding door.

Claims

1. A compact pocket door frame for a sliding door comprising: a header support having a first end and a second end forming a first length therebetween; first and second header spacers having a proximal end and a distal end forming a second length shorter than said first length therebetween, said header spacers secured to said header support and extending along said length of said header support; first and second header frame members secured to said first and second header spacers; a track fastened to a lower surface of said header support and nested between said first and second header spacers and said first and second header frame members, said track constructed and arranged to support a sliding door movable between said first and second end of said header support; a first vertical spreader spaced apart from a second vertical spreader by a first distance, each said spreader removably fastened, and extending from, said header support, and secured perpendicular to said proximal end of said header spacers; a base member having a having a front end and a back end forming a second length therebetween, said front end fastened to said first and second vertical spreader forming an opening sized to allow a sliding door to pass through said opening; a metal endplate attached to said second end of said header support, said metal endplate having a width measured between a first edge wall and a second edge wall; a first plywood panel positioned adjacent said first vertical spreader and extending from said base member to said header support and removably fastened to said header support; a first base block extending between said base member and said header support, said first base block secured to said first vertical spreader; a second plywood panel positioned adjacent said second vertical spreader and extending from said base member to said header support and removably fastened to said header support; and a second base block extending between said base member and said header support, said second base block secured to said second vertical spreader; wherein said header support is removably fastened to said vertical spreaders for shipping and storage whereby said header support is secured to said vertical spreaders forming a T-shape structure for wall mounting to support a sliding door.

2. The compact pocket door frame according to claim 1 wherein each said vertical spreader is made from laminated % inch primed finger joint pine.

3. The compact pocket door frame according to claim 1 wherein the base member is made of ? inch Polyethylene.

4. The compact pocket door frame according to claim 1 wherein said first plywood panel is about 14 inches wide.

5. The compact pocket door frame according to claim 1 wherein said second plywood panel is about 14 inches wide.

6. The compact pocket door frame according to claim 1 wherein a pocket recess defined between said first and second header spacers and said first and second header frame members is at least 4? inches wide.

7. The compact pocket door frame according to claim 1 wherein said metal endplate includes screw holes and cutouts to properly align and secure the frame assembly with screws or T-bolts during installation.

8. The compact pocket door frame according to claim 1 wherein said track is mounted to said header support with T-bolts and reciprocal fasteners.

9. The compact pocket door frame according to claim 1 wherein said first vertical spreader and said second vertical spreader include a plurality of door stop slats therebetween each secured by a slat block which covers a pocket recess entryway.

10. A compact pocket door frame for a sliding door comprising: a header support having a first end and a second end forming a first length therebetween; first and second header spacers having a proximal end and a distal end forming a second length shorter than said first length therebetween, said header spacers secured to said header support and extending along said length of said header support; first and second header frame members secured to said first and second header spacers; a track fastened to a lower surface of said header support and nested between said first and second header spacers and said first and second header frame members, said track constructed and arranged to support a sliding door movable between said first and second end of said header support; a first vertical spreader made of laminated ? inch primed finger joint pine spaced apart by 2? inches from a second vertical spreader made of laminated ? inch primed finger joint pine by a first distance, each said spreader removably fastened, and extending from, said header support, and secured perpendicular to said proximal end of said header spacers; a base member having a having a front end and a back end forming a second length therebetween, said front end fastened to said first and second vertical spreader forming an opening sized to allow a sliding door to pass through said opening; a metal endplate attached to said second end of said header support, said metal endplate having a width measured between a first edge wall and a second edge wall; a first plywood panel having a thickness of ? inch and a width of 14 inches positioned adjacent said first vertical spreader and extending from said base member to said header support and removably fastened to said header support; a first base block extending between said base member and said header support, said first base block secured to said first vertical spreader; a second plywood panel having a thickness of ? inch and a width of 14 inches positioned adjacent said second vertical spreader and extending from said base member to said header support and removably fastened to said header support; and a second base block extending between said base member and said header support, said second base block secured to said second vertical spreader; wherein said header support is removably fastened to said vertical spreaders for shipping and storage whereby said header support is secured to said vertical spreaders forming a T-shape structure for wall mounting to support a sliding door.

11. The compact pocket door frame according to claim 10 wherein the base member is made of ? inch Polyethylene.

12. The compact pocket door frame according to claim 10 wherein a pocket recess defined between said first and second header spacers and said first and second header frame members is at least 4? inches wide.

13. The compact pocket door frame according to claim 10 wherein said metal endplate includes screw holes and cutouts to properly align and secure the frame assembly with screws or T-bolts during installation.

14. The compact pocket door frame according to claim 10 wherein said track is mounted to said header support with T-bolts and reciprocal fasteners.

15. The compact pocket door frame according to claim 10 wherein said first vertical spreader and said second vertical spreader include a plurality of door stop slats therebetween each secured by a slat block which covers a pocket recess entryway.

16. A compact pocket door frame for a sliding door comprising: a header support having a first end and a second end forming a first length therebetween; first and second header spacers having a proximal end and a distal end forming a second length shorter than said first length therebetween, said header spacers secured to said header support and extending along said length of said header support; first and second header frame members secured to said first and second header spacers; a track fastened to a lower surface of said header support and nested between said first and second header spacers and said first and second header frame members, said track constructed and arranged to support a sliding door movable between said first and second end of said header support; a first vertical spreader made of laminated ? inch primed finger joint pine spaced apart by 2? inches from a second vertical spreader made of laminated ? inch primed finger joint pine by a first distance, each said spreader removably fastened, and extending from, said header support, and secured perpendicular to said proximal end of said header spacers; a base member made of ? inch Polyethylene having a having a front end and a back end forming a second length therebetween, said front end fastened to said first and second vertical spreader forming an opening sized to allow a sliding door to pass through said opening; a metal endplate attached to said second end of said header support, said metal endplate having a width measured between a first edge wall and a second edge wall; a first plywood panel having a thickness of ? inch and a width of 14 inches positioned adjacent said first vertical spreader and extending from said base member to said header support and removably fastened to said header support; a first base block extending between said base member and said header support, said first base block secured to said first vertical spreader; a second plywood panel having a thickness of ? inch and a width of 14 inches positioned adjacent said second vertical spreader and extending from said base member to said header support and removably fastened to said header support; and a second base block extending between said base member and said header support, said second base block secured to said second vertical spreader; wherein said header support is removably fastened to said vertical spreaders for shipping and storage whereby said header support is secured to said vertical spreaders forming a T-shape structure for wall mounting to support a sliding door.

17. The compact pocket door frame according to claim 16 wherein a pocket recess defined between said first and second header spacers and said first and second header frame members is at least 4? inches wide.

18. The compact pocket door frame according to claim 16 wherein said metal endplate includes screw holes and cutouts to properly align and secure the frame assembly with screws or T-bolts during installation.

19. The compact pocket door frame according to claim 16 wherein said track is mounted to said header support with T-bolts and reciprocal fasteners.

20. The compact pocket door frame according to claim 16 wherein said first vertical spreader and said second vertical spreader include a plurality of door stop slats therebetween each secured by a slat block which covers a pocket recess entryway.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a perspective view of a compact pocket door frame assembly;

[0018] FIG. 2 is a side view thereof;

[0019] FIG. 3 is a side view thereof including a door on a sliding track;

[0020] FIG. 4 is a side view thereof including the door on the sliding track relocated to the other side;

[0021] FIG. 5 is a top view of a header support;

[0022] FIG. 6A is a side view of the header support;

[0023] FIG. 6B is a front view of a metal endplate;

[0024] FIG. 7A is a side view of the frame assembly with the header support attached to the frame in a storage position;

[0025] FIG. 7B is an end view thereof;

[0026] FIG. 8 is a cross-sectional view of the header support; and

[0027] FIG. 9 is a bottom view of the compact pocket door frame assembly without the header support.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0028] A detailed embodiment of the instant invention is disclosed herein; however, it is to be understood that the disclosed embodiment is merely exemplary of the invention. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representation basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

[0029] Referring now to the figures, illustrated is a compact pocket door frame 10 for a sliding door hung from a header support 12 having a length (L1) and a width (W1). The header support 12 spans from a first end 24 to a second end 26. A track 14 is attached to the header support 12 by use of a plurality of T-bolts 15 wherein a reciprocal fastener is removably attached to each T-bolt 15, allowing ease of track 14 maintenance or replacement.

[0030] A first header spacer 16 is positioned perpendicular to a lower surface of the header support 12 and extends outwardly from the pocket recess. A first header frame member 18 is positioned perpendicular to the first header spacer 16 and extends outwardly from the pocket recess. The first header spacer 16 is stapled and glued to the header support 12. The first header frame member 18 is stapled and glued to the first header spacer 16. A second header spacer 20 is positioned perpendicular to a lower surface of the header support 12 and extends outwardly from the pocket recess. A second header frame member 22 is positioned perpendicular to the second header spacer 20 and extends outwardly from the pocket recess. The second header spacer 20 is stapled and glued to the header support 12. The second header frame member 22 is stapled and glued to the second header spacer 20.

[0031] The track 14 is nested between the first and second header spacers 16, 20 and the first and second header frame members 18, 22. This region is referred to as the pocket recess. In a preferred embodiment, the pocket recess has a width of at least 4? inches.

[0032] The first header spacer 16 and the first header frame member 18 attached thereto extend from a proximal end 28 to a distal end 30. In a preferred embodiment, the proximal end 28 is located close to the middle point of the header support 12, but the distance between the distal end 30 and the proximal end 28 may span any distance shorter than the distance between the first end 24 and the second end 26. During installation of the compact pocket door frame assembly 10, the proximal end 28 is used as a stopper to ensure no side to side movement of the track.

[0033] A first vertical spreader 32 and a second vertical spreader 34 extend from a base member 35 to the header support 12 in a spaced apart position. The first vertical spreader 32 is spaced apart from the second vertical spreader 34 by a first distance and each spreader 32, 34 is removably fastened and extending from the header support 12 and secured perpendicular to the proximal end 28 of said header spacers 16, 20. In a preferred embodiment, the base member 35 is made of ? inch Polyethylene for reduced friction, damage prevention, corrosion resistance, low cost, and ease of installation. In this embodiment, the base member 35 has a thickness of ? inch and a length of 14? inch.

[0034] Each vertical spreader 32, 34 is made from laminated 3% inch primed finger joint pine and is stapled and glued to the header support 12 forming a spaced apart opening of about 2? inches (W1). The first vertical spreader 32 forms an L shape by use of a laminated base block 36 forming a width (W2) of about 1? inches with the base block 36 glued and stapled to the vertical spreader 32. Similarly, the second vertical spreader 34 forms an L shape by use of a laminated second base block 38 forming a width (W3) of about 1? inches with the second base block 38 glued and stapled to the second vertical spreader 34.

[0035] The first and second vertical spreaders 32, 34 form a pocket recess entryway, or opening, constructed and arranged to receive a sliding door 40, shown in FIGS. 3 and 4. FIG. 3 shows the sliding door 40 secured to the track 14 wherein a user can pull the handle 42 in order to move the sliding door 40 along the track 14. FIG. 4 shows the sliding door 40 secured to the track 14 relocated to the other side, wherein the sliding door 40 may be pushed through the pocket recess entryway, or opening. The compact door frame assembly 10 is originally constructed with a plurality of door stop slats 44 each secured to the first vertical spread 32 and the second vertical spread 34 by a slat block 46 which covers the pocket recess entryway. During installation, both the door stop slats 44 and the slat blocks 46 are removed before inserting a sliding door 40 onto the track 14.

[0036] A metal endplate 48 is attached to the second end 26 of the header support 12 having a width measured between a first edge wall and a second edge wall. This width is defined by the region where the compact pocket door frame assembly 10 is installed between two drywall panels. The purpose of the metal endplate 48 is to provide structural support and stability to the compact pocket door frame assembly 10, in particular, with sagging and flexing of the frame assembly 10. A detailed view of the metal endplate 48 is shown in FIG. 6B. The metal endplate 48 includes screw holes 50 and cutouts 52 to properly align and secure the frame assembly 10 with screws or T-bolts during installation. Once properly installed, the metal endplate 48 helps maintain the integrity of the frame during the opening and closing of the sliding door 40.

[0037] Along the first side of the compact pocket door frame assembly 10 is placed a first plywood panel 54 positioned adjacent to the first vertical spreader 32 and extending from the base member 35 to the header support 12, the plywood being ? inch thick and about 14 inches wide, and being attachable to the header support 12 by securing screws or T-bolts through the top of the first plywood panel 54. The second side has a second plywood panel 56 positioned adjacent to the second vertical spreader 34 and extending from the base member 35 to the header support 12, the plywood being ? inch thick and about 14 inches wide and fastened to each of the horizontal slats 34 positioned on the second side, and being attachable to the header support 12 by securing screws or T-bolts through the top of the second plywood panel 56.

[0038] The combination of the vertical spreaders 32, 34 and the plywood panels 54, 56 are positioned about halfway along the length of the header support 12. The header support 12 is removably fastened to the vertical spreaders 32, 34 for shipping and storage whereby the header support 12 is secured to the vertical spreaders 32, 34 forming a T-shape structure for wall mounting to support a sliding door 40.

[0039] FIGS. 7A and 7B show the compact pocket door frame assembly 10 in a storage or shipping position. The present invention solves the issue of storage and shipping large door frame assemblies by allowing the entire length of the header support 12 to fit directly over and onto the vertical spreaders 32, 34, wherein the header support 12 is sized and shaped width-wise substantially similar to the distance between the first vertical spreader 32 and the second vertical spreader 34, allowing the entire frame assembly 10 to be stored or shipped neatly in one vertical container.

[0040] As shown in FIG. 7B, the edges of the header frame members 18, 22 meet the edges of the vertical spreaders 32, 34 and the pocket recess does not allow for interference with the track 14 or even the door stop slats 44 and slat blocks 46. The header support 12 can be secured to the vertical spreaders 32, 34 with screws or T-bolts during storage and shipping, which are later removed during installation. The screws or T-bolts can then be removed, making the header support 12 a stand-alone piece, and then placed, fit, and secured directly to the top surface of the vertical spreaders 32, 34 forming a T-shape structure for wall mounting to support a sliding door 40.

[0041] The term about means, in general, the stated value plus or minus 5%. The use of the word a or an when used in conjunction with the term comprising in the claims and/or the specification may mean one, but it is also consistent with the meaning of one or more or at least one. The terms comprise (and any form of comprise, such as comprises and comprising), have (and any form of have, such as has and having), include (and any form of include, such as includes and including) and contain (and any form of contain, such as contains and containing) are open-ended linking verbs. As a result, a method or device that comprises, has, includes or contains one or more steps or elements, possesses those one or more steps or elements, but is not limited to possessing only those one or more elements.

[0042] One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims.