US 3100917 A
Description (OCR text may contain errors)
Aug. 20, 1963 R. c. WAGNER PLASTIC FRAME CONSTRUCTION Filed May 9, 1961 INVENTOR.
QM C, uw! BY United States Patent O 1 3,100,917 PLASTIC FRAME CGNSTRUCTIN Robert C. Wagner, RR. 4, Bellevue, Ohio Filed May 9, 1961, Ser. No. 108,871 2 Ciaims. (Cl. 20u16) This invention relates to frames, such las door `and window frames and sashes, `and particularly to a frame which is fabricated from extrusions of set synthetic organic plastic.
rPhe principal object of the invention is to provide a fname of this character which is precisely shaped and which is reinforced in a manner such that whipping and bowing of the frame out of its normal plane are greatly reduced.
For the purposes of illustration, the invention is described as applied to a vinyl frame for screen or glass pane doors, its application to other types of plastic and frames being readily apparent from the illustrative eX- K ample.`
i Heretofore, in the formation of vinyl door frames, attempts have been made to obtain suiicient rigidity to prevent the fname from warping, bulging, Ior bowing out of its normal plane and to eliminate the so-called whip, by increasing the wall thickness. The whip is particularly objectionable because it prevents the doors from seating properly in the door jamb `and also results in tth breaking of the glass panes.
When such doors are closed with obstructing foreign objects between the door frames tand jambs, the doors flex. If a door is held by the latch in flexed condition for a predetermined period, it warps permanently in the flexed shape.
These iframes almost lalways are fabricated from rails cut from plastic extrusions which are hollow or tubular so as to provide maximum rigidity with as chin walls as possible, thus reducing the amount of the relatively expensive plastic required.`
To increase the vertical rigidity and reduce bowing, metal reinforcing tubes or channels of aluminum or steel have been inserted inside the `hollow or tubular extruded rails, and gussets have been used to reinforce the frames at the corners. rihis type yof construction is very expensive due to complex fabricating steps required and inconsistent results obtained. To eliminate this diiiicwlty, an attempt was made to Weld or fuse the reinforcing members and gussets together at the corners, and while a fairly rigid door could be obtained by this method, some whip remained 'and introduced sales objections, and the welding operation was very expensive.
Another approach was to eliminate the use of the its rejection. For example, the 'addition of webs and ribs did not yield sufficiently increased strength to prevent bowing of the door, and they caused deformities in the face of the extrusion at their junctures therewith. These deformities adversely saifelcted the appearance and market desirability. Again, consistent tolenances could not be obtained on successive extrusion runs.
In accordance with the Ipresent invention, the frame of extruded plastic is so arranged that la simple hollow or tubular extruded section `of aluminum or like material can be secured thereto easily and cooperate therewith to reinforce the frame adequately and thereby reduce warp ing and whipping to an unobjectionable amount.
Various other Iobjects and advantages will become apparent from the following description wherein reference is made of the drawings, in which:
FG. 1 illustrates a front elevation of a door frame embodying the principles of the present invention;
FlG. 2 is an enlarged fragmentary View of the upper right-hand corner of the frame illustrated in FIG. l, partly in section, showing the arrangement of the 'frame rails and the connection of the reinforcing members; and
FIGS. 3 and 4 are enlarged cross sectional views taken on the lines 3 3 and 4 4, respectively, in FIG. l. g
Referring to the drawings, lthe door frame comprises essentially a pair of spaced side rails or frame members 1 with cross end rails or iframe members E connected to the ends thereof. lf desired, la suitable cross rail or frame member 3 may be provided intermediate the ends of the side frame members 1. The side frame members 1 and the end frame members 2 are lengths cut from identical extrusions of vinyl or suitable set plastic, such as high impact plastic. Each comprises a hollow tubular portion 5 having an outer decorative side Wall 6 and an inner side wall 7, joined by an outer peripheral wall 8 and inner periphenal wall 9. The wall 9 has a flange 10 extending inwardly of the fra-me parallel to the walls 6 and 7 and offset from the planes thereof so as to act as a stop for a `framed Screen or pane installed in the opening defined by the wall 8. The frame members are tubular and, when assembled, the outer wall S is exposed outwardly of ,the finished door edgewise of the door. rllthe assembled frame has mitered corners, the frame members being bonded together at the corners 'by fusion of the plastic material at the juuncture, either 'by heat or plasticizers. Thus the vinyl frame becomes a unitary structure.
The side walls 6 and 7 have integral flanges 11 which, together with the wall 8, define an outwardly open peripheral channel 1?.. The anges 11 are formed with shoulders or fabutments 13 whichprotrude inwardly from the flanges and restrict the side of the channel 12. As a result, the channel 12 can receive and lsnugly `accommodate a tubular reinforcing member, such as indicated The tubular member 14 preferably is one having an y i and the outboard face of the wall 15 is engaged along its margins `by the inner faces of the abutments 13 land thus -held securely in the channel. The walls 17 of the member 14 preferably are juxtaposed in face to face relation with the inner faces of the flanges 1li and 11. lf desired, the member 1li may be cemented in place, thus increasing the rigidity of the frame.
The member 1li is a tubular extrusion, preferably of aluminum or like metal, and preferably is reinforced interiorly. On its inner wall 16, it is provided with integral channels 1S which are so con'gured as to reinforce the inner wall 16. The open sides `of the channels 18 are restricted so that the channels provide longitudinal open sided passages 19. These passages are adapted to receive screws, as indicated at 20, in coaxial relation therewith for securing the reinforcing members 14 together to form a mitered corner. By the use of self-threading screws, the members 14 can 'be drawn tightly together at the corners of the frame. The passages 19 extend longit=udinally of the members 14 and are preferably coeXtensive with the length thereof.
Whenithe members 14 are assembled together, as illustrated in FIG. 2, they completely embrace the frame, each side frame member 1 and top frame member Z being provided with a. reinforcing member 14 coextensive in length therewith. The screws 20 are introduced through the reinforcing members of the side frame members by boring suitable horizontal holes therethrough in alignment with the passages 19 in the channels 1S. The screws 20 are then passed therethrough and threadably engage the walls of the channels 1S by cutting their own threads Patented Aue'. 20, 1963 e.y l
therein. rThey draw .the members 14 of the side frame members 1 and of the top and bottom fra-me membersV Z xedly together in position, so that they tightly embrace the peripheral edge of the frame. Thus, no welding isV required and, a rigid reinforced door ystructure is provided without increasing the thickness of the walls of plastic extrusion and without internal webbing and the like. If facilities for welding `are available, the members `f4 may be connected together by welding, which, since With this arrangement, the `door frame is reinforced' and is made sufficiently rigid Without an increase in the thickness of the'walls of the plastic material and With- Vout expensive webbing. Likewise, the combination can be effected without welding internal reinforcing members and without specialized equipment, by the insertion of ordinary self-threading screws.
However, if welding of the reinforcing members is desired, such can be effected more readily as the reinforcing members are exposed exteriorly of the rframe. Thus a frame of extrusions of vinyl or synthetic organic plastic material is provided which. has mitered fused corners and reinforcing members which rare readi-ly fastened together after the frame is otherwise compiete.
` its outer edge a pair of integral flanges inspaced face to In those instances where the corners `formed by the A complete in and lof itself, of extruded tubular side, top,
and bottom frame members of identical cross section throughout their lengths and of set 'organic plastic mate rial having mitered joints fusion bonded together in xed position relative to each other `at the corners, respectively, of the frame, each of said main frame members having at face relation to each other and extending lengthwise of said outer edge the full length thereof and deining with said outer edge a rohannel which opens outwardly edgewise of the main frame, the channels of said members defining a continuons channel extending completely about the outer peripheral edge of the main frame and opening outwardly edgewise of the main frame, la reinforcing frame complete in and of itself of stiff metal side, top, and bottom reinforcing members, respectively, said reinforcing iframeV being dis-posed in said channel and juxtaposed against the edges of the main frame therebetween and filling the space between 'the flanges and having rniteredv joints at the corners, respectively, the corners of the reinforcing frame being disposed for access exteriorly of the main frame for connection of the reinforcing members together at the corners in iirm embracing relation to the main frame, connecting means at the corners .of the reinforcing frame, respectively, each of said connecting mea-ns including at least one screw assembly, at its associated corner, for operation from the exterior of the reinforcing frame, each connecting means securing its associated reinforcing members together at the tass'ociated'mitered corner of the reinforcing frame independently of the main frame and holding the mitered surfaces of the associated reinforcing members in rm stressed juxtaposition with each other under pressure applied by the screw; v
2. The structure according to olaim 1 Whereineacrh screw extends through one of the reinforcing members, edgewise thereof from the outer edge of the reinforcing frame with its 'head rat the outer edge, and is slidable axially thereacross l`and has a threaded inner end portion extending endwise of the other reinforcing member at the associated corner and in threaded engagement therewith, so that upon rotation of the screw said mitered edges of Vthe associated reinforcing member can be drawn thereby into said stressed relation.
References Cited in the le of this patent UNITED STATES PATENTS