Door frame creation kit

Abstract

The object of the invention is a door frame creation kit, being in a both rebated as well as non-rebated variants, having three parts: a first band, a main beam and a second band, wherein the first band, the main beam and the second band - are made of lignocellulosic materials and composite materials composed of, among other things, thermoplastic polymer, wood dust, resin and additives and fillers, wherein the first band and the main beam have respectively the same construction for use in both rebated and non-rebated variants, wherein the second band constitutes a masking band of the finished frame and in the rebated variant is in the form of an angled piece with one masking arm and a second fastening arm, in the non-rebated variant is in the form of an angled piece with one masking arm and the second fastening arm, whereby on the fastening arm, from the side of the masking arm - there is a distancing thickening.

Description

[0001] The present invention relates to the field of door frames, and more specifically to adjustable door frames, formed from several elements - two bands and the main beam of the door frame, which are dedicated in particular for interior use.

[0002] In the prior art various types of door frames are known - both those that are later used to mount doors on them, as well as just a kind of "masking tunnels" mounted in openings in the walls, forming decorative portals.

[0003] Whenever door frames are mentioned - it should be noted that the prior offers numerous different construction variants available, in which many different types of materials are observed - from natural, solid wood, through various types of chipboards, plywood and the like and even door frames made of plastic or metal, to various types of composite materials.

[0004] The choice of the right material, on the of the consumer / buyer side, usually depends on the price of the product and the desired aesthetic aspects. At the same time, it should also be noted, that according to the region of the world - one observes typical dominant groups / types of door frames, among which one can distinguish: door frames for rebated doors, door frames for non-rebated doors, of the Asian type (in which the door leaf has a flat side / even edge, but in the closed state the door is near the center of the doorway and such doors can only be opened to an angle of much less than 180 degrees) door frames for non-rebated doors, of the European type (in which the door leaf has a flat side / even edge, but in the closed state the door is flush with the outside of the door frame and can be opened to an angle much greater than 90 degrees, and depending on the installed hinges - it is possible to open the door to an angle of up to 180 degrees).

[0005] However, it turns out that when selecting door frames for installation in a given e.g. house / apartment - some walls / partitions have greater or lesser thickness than others. In view of this - door frame manufacturers have been forced over the years to provide a wide variety of types / dimensional variants of door frames (or parts that make up the door frames) to meet the demand of customers who expect the frames to look essentially uniform throughout their apartment / home, regardless of how thick or thin the walls in question are. As a result - manufacturers are forced to prepare multiple variants of essentially the same product, which may additionally come in rebated or non-rebated versions.

[0006] Even when door frames are assembled from three parts - two bands and a main / center beam - it turns out that manufacturers still have to prepare at least five variants of the parts in question - i.e. an adjusting band, a rebated main beam, a non-rebated main beam, a rebated masking band and a non-rebated masking band.

[0007] This necessity means that, for a given manufacturer to provide a line of door frames matching the given expected and most typical wall / wall thicknesses - one has to realistically prepare dozens of door frame parts, which is uneconomical, excessively labor-intensive and cumbersome - particularly due to the need to store a large amount of materials.

[0008] In addition, it turns out that many of the door frames available on the market are door frames formed from wood or plywood / chipboard, etc., which are highly desirable materials in most applications, however, which when in contact with water or when remaining for a long time in rooms with high humidity (e.g., bathroom, laundry room, sauna, etc.) - they can get destroyed.

[0009] In view of these needs and challenges - the present solution has been developed, which on the one hand reduces the number of parts needed to create door frames, and also thanks to the use of a material that can be used without risk in rooms with high humidity - improves utility values.

[0010] The object of the invention is a door frame creation kit, being in a both rebated as well as non-rebated variants, having three parts: a first band, a main beam, a second band, wherein the first band, the main beam and the second band - are made of lignocellulosic materials and composite materials composed of, among other components, thermoplastic polymer, wood dust, resin and additives and fillers, wherein the first band and the main beam have respectively the same construction for use in both rebated and non-rebated variants, where the first band constitutes an adjusting band of a finished frame, having the form of an angled piece with one masking arm and the second fastening arm, where the main beam constitutes the middle part of the finished frame and has on its two opposite sides two attaching slots, i.e. a first and a second attaching slots, adapted for mounting in them the fastening arms of the first and second bands, respectively, wherein the second band constitutes a masking band of the finished frame and in the rebated variant is in the form of an angled piece with one masking arm and a second fastening arm, in the non-rebated variant is in the form of an angled piece with one masking arm and the second fastening arm, whereby on the fastening arm, from the side of the masking arm - there is a distancing thickening.

[0011] Preferably, the second band has a structure respectively: in the rebated variant - the fastening arm is in the form of a solid strip of material, while the masking arm has a chambered structure with compacted chambers in the zone from the side of the fastening arm, in the non-rebated variant - the masking arm has a chambered structure, distancing thickening has a chambered structure, while the rest of the fastening arm has the form of a solid strip of material.

[0012] Preferably, the fastening arm of the first band has at least one groove, which runs along the first band and indicates the line to cut and thus evenly shorten this fastening arm.

[0013] Preferably, the groove runs spaced from 10 mm to 30 mm, especially 20 mm, from the end of the fastening arm of the first band.

[0014] Preferably, the main beam, from its side with the second fastening slot, has a structure with compacted chambers.

[0015] Preferably, the main beam has a width, between its side with the first fastening slot and the side with the second fastening slot, of between 70 mm and 340 mm, especially being 86 mm, 126 mm, 166 mm, 206 mm, 246 mm, 286 mm or 326 mm.

[0016] Preferably, the thickness of the main beam is from 18 mm to 44 mm, especially 22 mm.

[0017] Preferably, the first band has a width, measured along its fastening arm, of between 56 mm and 70 mm, especially 64 mm.

[0018] Preferably, the second band, in the rebated variant, has a width, measured along its fastening arm, of between 36 mm and 56 mm, especially 44 mm.

[0019] Preferably, the second band, in the non-rebated variant, has a width, measured along its fastening arm, of between 52 mm and 70 mm, especially 60 mm.Brief description of drawings

[0020] The present invention will be further described below in preferable embodiments and with reference to the accompanying drawing, in which, in cross-section: Fig. 1 and Fig. 2 show two embodiments of the first band, Fig. 3 and Fig. 4 show two embodiments of the second band, in a rebated variant, Fig. 5 and Fig. 6 show two embodiments of the second band, in the non-rebated variant, Fig. 7 shows embodiments of different dimensional variants of the main beam, Fig. 8 shows embodiments of the finished frame in different size variants, in the rebated version on the left and in the non-rebated variant on the right, Fig. 9 shows an embodiment of a finished frame, installed on the wall with a visible door leaf, in the non-rebate variant, Fig. 10 shows an embodiment of a finished frame, installed on a wall with a visible door leaf, in the rebated variant. List of numeric references:

[0021] 1 - first band 11 - masking arm of the first band 12 - fastening arm of the first band 13 - groove 2 - main beam 21 - first attaching slot 22 - second attaching slot 3a - the second band, in the rebated variant 3b - the second band, in the non-rebated variant 31 - masking arm, in the rebated variant 32 - fastening arm, in the rebated variant 33 - masking arm of the second band, in the non-rebated variant 34 - fastening arm of the second band, in the non-rebated variant 35 - distancing thickening Detailed description of the invention

[0022] The door frame creation kit, in the most general terms, has three main components - these are the first band 1, the main beam 2 and the second band, which comes in two variants, i.e. the rebated variant 3a and the non-rebated variant 3b. This provides the user with the freedom to adapt the door frame kit to different door variants (rebated and non-rebated), using the same first bands 1 and main beams 2 and selecting only the second band according to the desired rebated variant 3a or non-rebated variant 3b. As a result, door frame manufacturers need to provide the parts in question (especially - main beams 2) only in the corresponding dimensional variants (cf. e.g. Fig. 7 and Fig. 8), and the need to provide main beams and one of the bands in two variants (non-rebated and rebated) is reduced only to the need to provide the given non-rebated or rebated bands. Thus, instead of the previously common provision of five parts to create door frames for a given dimension, manufacturers can produce only four, with the production, cost and material effort involved in producing the bands being significantly less than the effort involved in producing the main beams.

[0023] The aforementioned elements, i.e. the first band 1, the main beam 2 and the second band 3a, 3b, can be made of various materials (e.g. wood, plywood, chipboard, etc.), but because of the desired moisture resistance properties - they are made of composite-based materials, containing in their composition, among other things, wood dust, polymer material and fillers and additives.

[0024] The primary component of the used composite material is a thermoplastic polymer selected from a group including polyvinyl chloride, polypropylene, polyethylene or polystyrene, the content of which can range from 20% by weight to 70% by weight, for example, it can be 45% by weight. The use of the abovementioned polymer contributes to increasing the strength of the material due to its resistance to various chemical agents, biocorrosion or adverse environmental conditions (especially - moisture). In addition, the material used is characterized by plasticity, so that the door frame material can be easily molded at the stage of production, making it possible to obtain complex shapes or cross-sections with a varied internal structure.

[0025] Another component of the used composite material are plant-based materials containing lignin and cellulose (called lignocellulosic materials), and an example of such a material used in a composite is wood dust. The content of wood dust can range from 3% by weight to 50% by weight, for example, it can be 20% by weight. The use of wood dust allows the use of wood waste, reducing production costs.

[0026] The use of a combination of thermoplastic polymers with a lignocellulosic material, on one hand, provides a material that is not strictly a plastic material (which consumers do not often choose to buy due to prejudices against this type of material related to, among other things, ecology), but a material that is partially wooden while retaining many of the technical advantages of plastics, particularly with regards to e.g. water resistance, and thus will be a material suitable for use in rooms with increased humidity such as bathrooms, saunas and laundry rooms; in addition, it is resistant to pests, fire and some chemicals.

[0027] Another component of the composite material used is the filler, which can be calcium usually in the form of calcium carbonate. The filler content can range from 10% by weight to 60% by weight, for example, it can be 25% by weight. The use of such a filler increases the stability and density of said composite. The use of calcium carbonate, since it is a relatively inexpensive and widely available material, reduces production costs, while allowing to achieve good mechanical properties of the final material.

[0028] The other components of the composite material are utilized technological additives. Such additives can be modifiers, plasticizers, waxes or dyes, among others. The content of additives can range from 3% by weight to 20% by weight, for example, it can be 15% by weight.

[0029] In one preferable embodiment, the composite material from which the components of the kit for creating door frames according to the invention are made, contains 45% by weight of polymer, 20% by weight of lignocellulosic material, 25% by weight of filler and 15% by weight of technological additives.

[0030] The door frame components have a non-accidental geometry that allows the user to conveniently mount them on the wall (in the doorway) to form a finished frame, as well as this design provides benefits in terms of versatility of use and the reduced number of parts that frame manufacturers must provide.

[0031] The first band 1 is in the form of an angled piece with one masking arm 11 and a second fastening arm 12. Such a first band constitutes an adjusting band of the finished door frame. The adjusting function of the first band 1 allows to adjust it during installation so that it adheres to the wall in the desired way - by placing its fastening arm 12 deep enough in the corresponding slot 21 in the main beam 2. This allows to compensate for imperfections in the construction of walls or partitions, in relation to the main supplied dimensional variants of the main beams 2 and possibly also the first bands 1. The fastening arm 12 of the first band 1, if a very precise fit is required, can be cut to size during installation and the remainder of it can be mounted so that the first band 1 completely contacts the wall or so that the desired spacing is created.

[0032] The masking arm 11 of the first band 1 covers the given edge of the doorway and the materials and fastening means with which the door frame, especially its main beam 2, is installed in the doorway.

[0033] The main beam 2 has on its two opposite sides two fixing slots, i.e. the first 21 and the second 22 fixing slots, adapted for fixing in them the fastening arms of the first 1 and the second 3a, 3b bands, respectively. The main beam has two sides, a left side and a right side, with one fixing slot on each side, and the middle part of the beam extends between them. Main beams 2 also have a front surface and a rear surface. The front surface, which is visible in the assembled door frame and faces the inside of the door opening; the rear surface, which remains invisible in the assembled frame, faces the wall.

[0034] In preferred embodiments, on one side of the main beam 2 there is an attachment groove into which a door seal can be installed.

[0035] It is also possible to manufacture and assemble door frames without gaskets mounted in such a fixing groove, but e.g. adhering gaskets on the main beam 2 along its length - then, at the point of the fixing groove, the given main beam 2 would have a locally flat surface.

[0036] Preferably, the first 21 and second 22 fixing slots of the main beam 2 are adapted for mounting therein the fixing arms 12, 32, 34 of the bands in a press-fit manner, that is, the width of the slots is slightly smaller than the width of the said fixing arms.

[0037] In another embodiment, the first 21 and second 22 fixing slots are as wide as or slightly wider than the fixing arms 12, 32, 34 so that there is little or no spacing during assembly, so that additional adhesive or other type of bonding agent / glue can be used or the components can be joined by high-temperature bonding.

[0038] In one of the preferred embodiments, the first slot 21 has a depth provided such, that the mounting arm 12 of the first tie 1 mounted therein can enter it whole, or be shortened and not reach the bottom of the slot, but so that in such situations the zone of contact between the slot 21 and the mounting arm 12 of the first band 1 still guarantees its stable fastening (so that by itself or under the influence of a small force - it does not fall from the main beam 2).

[0039] The second band 3a, 3b is the main element of the kit according to the invention, which ensures its versatility and allows to reduce the elements needed to create door frames. In general, this band has a structure (viewed in cross-section) - similar to the structure of the first band 1, i.e. it has the form of an angled piece with two arms.

[0040] In both variants of the second band 3a and 3b - one of the arms is a masking arm 31, 33, which in the assembled state performs the same functions as the masking arm 11 of the first band 1. However, the internal structure of the masking arm 31, 33 of the second band 3a, 3b changes depending on whether it is the band in the rebated variant 3a or the non-rebated variant 3b.

[0041] On the other hand, the fastening arm 32, 34 of the second band 3a, 3b is the element where the biggest design differences can be seen, i.e.: the fastening arm 32 in the rebated variant - has, in principle, a simple design, which can be compared to a relatively thin and flat piece of material that is adapted to be placed in the second fixing slot 22 of the main beam 2; the fastening arm 34 in the non-rebated variant - is, in principle, longer than the fastening arm 32 of the rebated variant, also has a structure that can be compared to a thin and flat piece of material, but this structure is locally widened and from the side of the masking arm 33 - a distancing thickening 35 is present.

[0042] Such a distancing thickening 35 makes it so that when the door frame is to work with a non-rebated door - sufficient space is provided for such a door to be flush with the outer surface of the masking arm 33 when closed (see Fig. 9). Also - due to the necessity of mounting door accessories (parts of locks, hinges, etc.) on this part of the door frame - such a distancing thickening 35 advantageously influences the strength of the second band 3b in this zone and makes it possible to place screws, etc., in it.

[0043] Preferably - such distancing thickening 35 has a thickness that corresponds to the thickness of the part of the main beam 2 between the second fastening slot 22 and the rear surface of the main beam, which provides a relatively even surface on the wall side.

[0044] In some embodiments - it is preferable and desirable to reduce the weight of the elements for the creation of door frames, while maintaining their strength to a satisfactory degree - in such cases, the use of the composite material described above offers an advantage over wooden frames, as the parts of the frame according to the invention can be relatively freely formed internally.

[0045] Preferably, some parts have a partially preserved solid structure (e.g., mounting arms 32, 34), while other parts have a structure with reduced mass - especially a chambered structure (e.g., masking arms 31, 33). Also, parts of the main beam 2 may have a chambered structure - especially the middle parts, which are not locally subjected to high loads by themselves (no hardware is mounted in them, for example), and which mainly serve to provide adequate width to the main beams (see Fig. 7).

[0046] On the other hand, in order to allow at least a partial reduction of the weight of the given elements of the frame creation kit, but also to guarantee their correspondingly high mechanical strength - parts such as the distancing thickening 35 and the part of the masking arm 31, located in the zone on the side of the fastening arm 32 - advantageously have a structure with compacted chambers (cf. Figs. 3, 4, 5 and 6). Such a compacted structure is noticeably denser than the usual chambered structure that can be seen, for example, in the masking arm 11 of the first band 1.

[0047] In addition to the compacting of the chambered structure of the bands - the main beam 2 also advantageously has a compacted chambered structure (cf. Fig. 7), especially along its entire front surface. In addition to providing good strength and making the door frame resistant to damage that may occur when this part of main beam 2 is accidentally struck - it turns out that thanks to the thickening of the chambered structure, it is possible to obtain a smooth outer surface through which the partitions of the inner chamber structure will not be visible (which is a problem in many structures of plastic or composite materials that have a chambered structure).

[0048] Also - the main beam 2 advantageously has a structure with compacted chambers at the places that form the sides of the first 21 and the second 22 fixing slots - to guarantee adequate strength and connection strength with the fixing arms 12, 32, 34 of the bands.

[0049] Preferably - the main beam 2 also has a structure with compacted chambers in the interior in the part immediately adjacent to the second fastening slot 22, to allow in this part a stable and sturdy fastening of door hardware, such as lock / hinge parts.

[0050] Although the Figures show cuboidal chambered structures (with cross-sections of squares and wider or narrower rectangles) - it is obvious that it is possible that there are other shapes in which internal chambers (ordinary as well as in places with compacted structures) can be provided - there can be circles, ovals, triangles, trapezoids, pentagons, hexagons, etc. The used composite material allows for a great freedom in the design of such internal chambers, which do not even have to be of the same type (i.e., in some embodiments - for example, in main beam 2 there can be compacted chambers shaped like circles, and larger chambers in triangular cross-section).

[0051] Preferably, in some embodiments, the first band 1 is provided with at least one groove 13 on its fastening arm 12 running along said first band 1. This groove 13 runs in a predetermined distance from the end of the fastening arm 12, marking an even cutting line for the person mounting it, in case the first band 1 has to be shortened by a given length. Even though only one groove 13 is shown in the Figures - it is possible to provide more grooves 13 as needed, such as two, three, four or five or more grooves 13, marking out given cutting lines.

[0052] Preferably, when there is only one groove 13 - it is spaced at a distance of between 10 mm and 30 mm, especially being 20 mm from the end of the fastening arm 12 of the first band 1, since this is the length by which the first band 1 most often needs to be shortened.

[0053] To ensure that the kit according to the invention allows it to be attached to the most typical walls that appear on the European market - it is advantageous that its individual parts have the appropriate geometric dimensions, such as: width of the main beam 2 - of between 70 mm and 340 mm, especially being 86 mm, 126 mm, 166 mm, 206 mm, 246 mm, 286 mm or 326 mm; thickness of the main beam 2 - of between 18 mm and 44 mm, especially being 22 mm; the length of the fixing arm 12 of the first band 1 - of between 56 mm and 70 mm, especially being 64 mm; the length of the fastening arm 32 of the second tie in the 3a variant - being between 36 mm and 56 mm, especially being 44 mm; the length of the fastening arm 34 of the second band in the non-groove variant 3b being between 52 mm and 70 mm, especially being 60 mm; the length of the masking arm 11, 31, 33 of the bands - being between 50 and 90 mm, especially being 60 mm or 80 mm.

[0054] By producing a kit for creating door frames according to the invention, taking into account the proposed dimensional examples, it is possible to provide a product line suitable for use in the majority of door openings encountered in the European market and to ensure that all door frames and doors leaves in a given utility unit look consistent with standard products currently available on the market.

[0055] In turn, the use of the described composite material for the described construction of frame elements ensures that such frames will be resistant to moisture and biocorrosion, eliminating the need to replace damaged frames after a short period of use.

Claims

1. A door frame creation kit, being in a both rebated as well as non-rebated variants, having three parts: - a first band (1), - a main beam (2), - a second band (3a, 3b), wherein the first band (1), the main beam (2) and the second band (3a, 3b) - are made of lignocellulosic materials and composite materials composed of, among other things, thermoplastic polymer, wood dust, resin and additives and fillers, wherein the first band (1) and the main beam (2) have respectively the same construction for use in both rebated and non-rebated variants, where the first band (1) constitutes an adjusting band of a finished frame, having the form of an angled piece with one masking arm (11) and the second fastening arm (12), where the main beam (2) constitutes the middle part of the finished frame and has on its two opposite sides two attaching slots (21, 22), i.e. a first (21) and a second (22) attaching slots, adapted for mounting in them the fastening arms of the first (1) and second (3a, 3b) bands, respectively, wherein the second band (3a, 3b) constitutes a masking band of the finished frame and in the rebated (3a) variant is in the form of an angled piece with one masking arm (31) and a second fastening arm (32), in the non-rebated (3b) variant is in the form of an angled piece with one masking arm (33) and the second fastening arm (34), whereby on the fastening arm (34), from the side of the masking arm (33) - there is a distancing thickening (35).

2. The creation kit according to claim 1, wherein the second band (3a, 3b) has a structure respectively: in the rebated (3a) variant - the fastening arm (32) is in the form of a solid strip of material, while the masking arm (31) has a chambered structure with compacted chambers in the zone from the side of the fastening arm (32), in the non-rebated (3b) variant - the masking arm (33) has a chambered structure, distancing thickening (35) has a chambered structure, while the rest of the fastening arm (34) has the form of a solid strip of material.

3. The creation kit according to claim 2, in which the fastening arm (12) of the first band (1) has at least one groove (13), which runs along the first band (1) and indicates the line to cut and thus evenly shorten this fastening arm (12).

4. The creation kit according to claim 3, in which the groove runs spaced from 10 mm to 30 mm, especially 20 mm, from the end of the fastening arm of the first band.

5. The creation kit according to any of the previous claims from 1 to 4, in which the main beam (2), from its side with the second fastening slot (22), has a structure with compacted chambers.

6. The creation kit according to any of the previous claims from 1 to 5, in which the main beam (2) has a width, between its side with the first fastening slot (21) and the side with the second fastening slot (22), of between 70 mm and 340 mm, especially of either 86 mm, 126 mm, 166 mm, 206 mm, 246 mm, 286 mm or 326 mm.

7. The creation kit according to claim 6, in which the thickness of the main beam (2) is from 18 mm to 44 mm, especially 22 mm.

8. The creation kit according to claim 6 or 7, in which the first band (1) has a width, measured along its fastening arm (12), of between 56 mm and 70 mm, especially 64 mm.

9. The creation kit according to claim 6, 7 or 8, in which the second band, in the rebated (3a) variant, has a width, measured along its fastening arm (32), of between 36 mm and 56 mm, especially 44 mm.

10. The creation kit according to claim 6, 7, 8 or 9, in which the second band, in the non-rebated (3b) variant, has a width, measured along its fastening arm (34), of between 52 mm and 70 mm, especially 60 mm.

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