WO2002002897A2

WO2002002897A2 - Door frame mounting system

Info

Publication number: WO2002002897A2
Application number: PCT/TR2001/000028
Authority: WO
Inventors: Mahir Bukusoglu
Original assignee: Mensis Insaat Proje Dekorasyon Ithalat Ihracat San. Ve Tic. Ltd. Sti.
Priority date: 2000-07-03
Filing date: 2001-07-03
Publication date: 2002-01-10
Also published as: EP1392948A2; WO2002002897A3; AU2001282844A1

Abstract

The invention relates to an assembly for providing a door-frame system in a wall hole and an installation method thereof. Said assembly comprises buffers (10) mounted on the wall (13) surfaces, an intermediate distance set square adjustment assembly (11) for adjusting all plane and interval settings thereof (10) before being mounted on the wall, intermediate carrier profiles located on the buffers (1, 1a) and main frame profiles (2) located thereon (1). In the said assembly, there are provided a channel (3) on the main frame profiles (2), channel hinges (4b) arranged vertically onto said channel and door hinges (4a) located in the door wing. In order to adjust the plane setting sof the buffers (10), the said adjustment assembly (11) comprises intermediate distance adjustment plate (11a) located on the buffers (10), strings (11e) connected to said adjustment plate (11a), weights (11f) providing the said strings (11e) to extend downward due to gravitation.

Description

DOOR FRAME SYSTEM HAVING FOUR SETTINGS AND SET SQUARE ADJUSTMENT ASSEMBLY FOR DRY WALLS

Technical Field

The present invention is related to the construction sector and a special concern is given to a door frame system used at places such as offices, business centers, hotels, hospitals, and schools where room partitions are per ormed.

The invention is particularly related to a system that provides a simple, quick, and standard fixation of the adjustable door frame system profiles, that are produced for dry walls, into the empty wall parts (wall cavities) by a standard or by a special intermediary spacing, horizontal and vertical set-square adjustment.

Background of The Invention

Dry wall systems such as plasterboards, gaseous concrete and plaster blocks are final wall materials with respect to the characteristics that they are assembled quickly, they do not necessitate thick plasters, and their smooth surface material contents. With these dry wall systems, traditional systems such as wooden frames with front and back casings, profile door frames made up of double pieces with an adjustable thickness, and standard aluminum or plastic door frame etc. are used in general.

Today, doorframe systems can be used in two ways as before and after dry wall construction. Although the usage of both systems has their disadvantages in general, the disadvantages of traditional doorframe systems are as follows.

Perpendicular axis curve of the wall system exactly reflects to the doorframe, since the hinge system, a union means for the door leaf and frame, takes place above the main frame. By putting a wedge or squirting foam between the frame system and wall, the wall system's horizontal axis curve may be eliminated. Although this bad appearance has been tried to be eliminated with casing profiles, the moment force exerted on to the door frame cannot be fully transferred to the strong wall system by this wedging because of the profile difference between this casing profile and the frame profile. As time passes this causes wagging of the frame system and not to perform its function to support the door leaf as it is expected.

There is no opportunity to change the opening direction of the door leaf during or after the assembly, since the door hinge is fixed on the main frame by drilling or screwing.

It is necessary to adjust the hinge that is assembled on the main frame according to the door leaf. Since the frame system is formed by a 45° corner cutting, it is possible that the angle conjunction locations of the frame system could be damaged due to faults in the wall system.

Freight expenses and storage costs are high since the doorframe system is produced before it is brought to the construction place. It is also difficult to protect the veneered (coated) and varnished frames from the construction site factors until the assembly is completed.

As the door frame system is produced according to measures taken from empty wall parts that are necessary to be used, it becomes impossible to use it in the event of different measures.

Another problem in existing systems is experienced as the profiles are assembled to the wall and then as at the set-square is adjusted. The montage of the frame profiles, that is used in the empty wall parts left for door frames, to the wall is made in two phases as adjustment (intermediary spacing, horizontal and vertical set- square) and fixation (screw or chemical conjunctive) process. Said adjustment process is performed so that a net intermediary distance and a set-square adjustment opportunity on the horizontal axis are left for the frame profile to be located into the empty wall part. Special height adjustment apparatuses and plain wooden or PVC cotters are used for this process. The aim of the aforementioned fixation process is to anchor the frame system -performed with an intermediary spacing and a set-square adjustment- into the wall cavity. The screwing method or chemical conjunctive is preferred for this process generally.

Special apparatus used for the adjustment process (according to the degree of difficulty) entails special montage equipment and experienced assembly masters. In case of using simple cotters for the purpose of adjustment process, a skilled assembly master should make a sensitive adjustment. These special intermediary components extend the system's montage period, eliminate the simple montage principle, and the frame system's stability as an outcome of the high moment given by the heavy door leaf to frame in time.

Description of Invention

To eliminate the above mentioned drawbacks, the present invention aims to present an embodiment with the door frame system elements which have the characteristics of four adjustment parameters consisting of three axis and an intermediary distance in order to form a door frame at the cavities of dry walls such as plasterboard walls.

Another aim of the invention is to provide a method to form a fixation system of an intermediary distance and a set-square adjustment to be used with door frame systems.

In order to perform said objectives, the present invention comprises a new adjustment apparatus to adjust the lower fixation wedges in any plane in order to simply, reliably, and adjustably locate the U-formed system profiles which are cut in standard or special sizes into the wall cavities, wherein these wedges are fixed on lateral surfaces of the wall and whereon the intermediary bearing frame is located afterwards.

In addition to said fixation wedges, the apparatus performed according to this invention also comprises an intermediary supporting profile that is located on wedges which are adjusted by said adjustment apparatus in any plane to form the plain cut door frame system in the wall cavity and the main frame profile that is located on said supporting profile.

The apparatus performed according to the present invention also comprises the channel hinges that are located perpendicularly on a channel that is present on said main frame profile, the door hinges that are positioned on the door leaf, and a door supporting mount that prevents a door lock's bolt from straining the channel after it is positioned in said channel.

Thanks to the present invention;

an easy adjustment is provided even in walls that are vertically uneven (inappropriate plumb lines) in any respect, as the intermediary supporting profile is different from the main frame profile and as these can be positioned on fixation wedges which are balanced by the adjustment apparatus in any respect;

a horizontal hinge adjustment can be performed by the channel present along the main frame profile;

hinge direction and thus the door opening direction can be altered by the same channel present along the perpendicular main frame profile positioned on both sides of the intermediary supporter;

the hinge channel in the main frame profile fixed to the intermediary supporting profile (casing) functions also as the counterpart for the lock bolt in the door leaf; the drawbacks stemming from the screwing system can be removed by straining and thus tightening the hinges in the main frame profile channel with respect to the opening direction of the door leaf;

the U-shape that constitutes the intermediary supporting system can be assembled by the upper margin legs after being cut straightly, a convenient assembly is performed by making a straight cut on the frame profiles, and a well-arranged intermediary system can be formed even in askew walls by straight cuts.

The door frame system that can be adjusted according to the distance between the walls is provided by the intermediary supporting profile and the main frame profile which are cut in certain sizes and the combined at the construction filed. As the profile frame and main frame profile do not occupy much place, the freight cost is kept low.

The U-shaped lower fixation wedges are fixed by screws after certain adjustments are performed in specific intervals at the wall cavity where the frame is to be formed. Said adjustment are made by the aid of the intermediary space and set- square adjustment apparatuses.

Another objective of this invention is that, within the tolerance of intermediary spacing, the fixation wedges can be easily adapted on all walls with an unbalanced set square. All supplies required for the system assembly are presented in a packet and only a screwdriver is used to screw the fixation wedges in the packet to the wall. The entire auxiliary adjustment and connection elements necessitated during the assembly step are present in the standard packet. Regarding another objective of this invention, two plates with profile gripping channels, two separate mini-metal pipe weights serving as a plumb line and a one piece cord tying together the plate and pipes are comprised in this apparatus. The setup method of the fixation system having the intermediary spacing and the set-square balance that the present invention provides for door frame systems contains the following steps:

wedges are put and not fixed on the lateral and top sides of the door cavity that is present in the wall;

the intermediary support upper head profile are attached into the channels formed on the plates in the adjustment apparatus;

the adjustment apparatus is positioned/hanged to the mutual upper wedges on said lateral wall sides thanks to the nails (click);

- all wedges are balanced in two planes (x-y and x-z) thanks to the one piece cord system that is let from the positioned adjustment apparatus and are measured in one plane (y-z);

the horizontal intermediary distance is adjusted thanks to said plates on the adjustment apparatus and the intermediary support upper head profiles utilized as a reference;

the vertical intermediary distance is adjusted thanks to one of said plates on the adjustment apparatus and the main frame side profiles utilized as a reference;

wedges having their entire balance performed are fixed to the wall by tightening means such as screws;

the mechanism adjustment apparatus is removed from the assembly setting;

the intermediary supporting frame is positioned on said wedges by a process of pressing and sliding; and the main frame (2, 2a, 2b) is placed on said intermediary supporting frame (1 , 1a) such a way that for tolerating any possible inclination of the entire wall to inside or outside directions, the main frame (2, 2a, 2b) is placed inclined in an extent of plane adjustment unit measured (y-z) during performing (x-y and x-z) plane adjustments.

Said perpendicular (x-y) balance is performed by making the weight cords tangent with lower wedge surfaces that re present on the lateral wall surface during the setup step of said fixation system. As the adjustment apparatus comprises a double lined, one piece cord with a certain weight, the horizontal adjustment performed on the most top wedges is automatically transferred to the wedges on the lower level.

In other words, both the vertical and horizontal set-square balances of the lower fixation wedges are performed at the same time by the double corded plumb line apparatus that hangs out of the balance plates and ties the plates and lower weights by a double line; thus the wedges are fixed.

By removing the intermediary spaces of the intermediary support upper head profile that is utilized as a reference, of the balance plates, and of the mutual upper plane wedges on the lateral wall fronts the horizontal intermediary balance is performed and as the end fronts of said elements are joined together in this way, said horizontal set-square balance (x-z) is realized automatically.

The general curving amount, namely the inward and outward curving amount of the entire wall (on the y-z plane) is calculated by the vertical reference traces on wedges. In order to reach this aim, one line of the plumb line cord and the perpendicular traces on wedges positioned on the same side are taken into account. The trace number difference between the trace of the most upper level wedge wherefrom the plumb line cord is passed, and the trace of the wedge on the most lower level gives the curving amount of the entire wall. After the intermediary supporting profile is assembled on wedges, the main frame is assembled with an inclination that equals the measured trace number difference as the main frame is positioned; thus the axial inclination of the wall is tolerated.

After the required amount of assembly wedges is fixed for the frame system to be positioned into the wall cavity, the system becomes ready to position the main frame on itself. The frame profiles that are cut in desired sizes are practically and manually positioned on assembly wedges by pressing/sliding thanks to said system.

As the same profile system and the same connection elements are used for these said processes, provided that certain tolerances are followed, the frame assembly process becomes standard and simple.

Other advantages of the present invention is that it is used in wall cavities smaller than the standard packet sizes, it is simply adapted on any unbalanced wall by performing cuts as to the intermediary distance of present wall cavities, and that the entire auxiliary adjustment and connection elements required during assembly are provided in the standard packet.

Bried Description of the Figures

Figure 1- A perspective view of the entire disassembled apparatus.

Figure 2a-e A horizontal cross-sectional view of the position where the desired intermediary distance balance on the horizontal plane (x-z) of the wall cavity where the door frame system is to be positioned is performed by the aid of the U-shaped lower fixation wedge and where the present set-square error is removed.

Figure 3- A perspective view of the intermediary spacing and set-square balance apparatus positioned on the lower fixation wedge on the most upper and perpendicular level and a representative view of the horizontal intermediary distance, set-square and perpendicular curving adjusted by the intermediary support upper head. Figure 4- A representative view of how the intermediary distance and set- square balances of the lower fixation wedges positioned on the perpendicular lateral sides of the wall cavity are performed independently of the wall cavity by the aid of the apparatus hanged on the upper wedge.

Figure 5a-c A perspective view of the intermediary distance and set-square balance plate positioned on the lower fixation wedge to be placed on the top side of the wall cavity and a representative view of the main frame side profile reference and perpendicular intermediary distance adjustment.

Figure 6- A representative perspective view showing the hinge group and the profiles.

Figure 7a-b The frontal cross-sectional view of the door lock bolt of an alterable direction system and the hinges on the main frame profile system.

Reference Numbers

1- Intermediary support profile

1 a- Intermediary support upper head profile 1 b- Intermediary support lateral profiles

2- Main frame profile 2a- Main frame upper head profile

2b- Main frame lateral profiles

3- Mane frame channel

4- Hinge group 4a- Door hinge 4b- Channel hinge

5- Lock bolt

6- U-shaped upper side notches - Screw - Set screw - Door supporting mount (projection)

10- U-shaped assembly lower wedge 10a- Flare channel

10b- Adjustment (balance) marks

11- Intermediary distance and set-square balance apparatus 11 a- Intermediary distance balance plate

11 b- Plate holding hanger 11c- Horizontal intermediary distance profile holing channels

11d- Vertical intermediary distance profile holing cavity

11e- One piece plumb line cord

11f- Plumb line weight

12- Standard system packet 13- Wall

Detailed Description of Invention

A representative disassembled perspective view of the apparatus according to this invention is shown in Figure 1 , whereby it comprises firstly the wedges (10) positioned on the wall (13), the intermediary support profiles (1) positioned so that they clutch the wedges from top from both the spacing top and side front, and the main frame profiles that are placed to be assembled on these intermediary support profiles (1). In order to realize the assembly on the upper horizontal surface as it was performed on lateral surfaces, the intermediary upper head profile (1a) is assembled to the wedges (10) in the same manner. Also the disassembled perspective view of the hinge set (4) and the set-square balance apparatus (11) are also depicted in this figure. A perspective view of a standard system packet (12) serving as a box and/or a protection bag to carry the entire materials and to present all of them as one pocket is illustrated as well. In the wall cavity where the frame system is intended to be placed, the fixation wedges (10) that come from the packet is positioned for any 60-70 cm according to the thickness of the wall. The U-shaped fixation wedge (10) placed in the edge of the wall (13) is screwed into the wall by screw after the required assembly adjustments are performed. After this fixation process, the intermediary support profile (1) having the same inner structure shape with the outer surface shape of the fixation wedge (10) is fixed manually by pressing sliding said piece on this fixation wedge (10). The intermediary support profile (1) that is placed on the perpendicular surface of the wall cavity has a U-recess (indentation) (6) at the upper wall side for assembly convenience.

The representative fixed assembly perspective view of the intermediary support profiles (1) of said U-shaped assembly lower wedges (10) is depicted in Figure 2. The outer edges of the U-shaped lower fixation wedge (10) have the same shape and size with the inner edges of the shaped frame system profiles (1). The assembly of the frame system profile (1) on the lower fixation wedge (10) after it is placed provides a high stability even when a screw is not used, as both have the same shapes. Likewise, a horizontal cross-sectional view of the position where the desired intermediary distance and horizontal set-square balance are performed by the aid of an U-shaped lower fixation wedge (10) on horizontal and vertical planes of the wall (13) cavity where the door frame system is to be formed is illustrated in this figure. U-shaped assembly wedges (10) is fixed to the wall system by a screw (7) after the desired intermediary distance, horizontal and perpendicular set-square balances are made in order to make the frame system free of problems. Set- square adjustment can be seen in the other figures. In Figure 2, it is also viewed that assembly wedges (10) are assembled the both lateral sides and upper top surface of the wall (13). Doorframe system are embodied by means of front and backward movement of the assembly lower wedge (10) in the wall (13) cavity by horizontal and vertical directions. Set-square defectiveness and convex construction of the wall (13) in horizontal plane can be compensated by front and backward movement of the U-shaped assembly wedges (10) legs. ln Figure 3, it is illustrated that cross-section view of preferred intermediate distance and horizontal set-square adjustment which is carried out by means of U- shaped assembly lower wedge (10) horizontal and vertical directions of the wall (13) cavity in which the doorframe is embodied. In order to assemble and provide consisting working conditions of the doorframe system on the U-shaped assembly wedge (10), preferred intermediate distance is fixed to the wall (13) by a screw (7) after horizontal and vertical set-square adjustments performed. In the Figure 3 it is also viewed that assembly wedges (10) are assembled the both lateral sides and upper top surface of the wall (13). Doorframe system are embodied by means of front and backward movement of the assembly lower wedge (10) in the wall (13) cavity by horizontal and vertical directions.

In Figure 4, it is illustrated that the adjustment apparatus embodied in the wall cavity. Intermediary support upper head profile (1a) that shaped standard or special measures located between the intermediary distance balance plate (11a) by virtue of horizontal intermediary distance profile holding channels (11c) that embodied in front of the plates. Intermediary distance and set-square balance apparatus (11 ) is located on the U-shaped assembly lower wedge (10) embodied mutually at the top level of the wall cavity. These mutually two assembly wedges (10) are fixed by a screw to the wall in a manner that any cavity is prevented among the wedge (10), balance plate (11a) and profile (1a). By virtue of the fixation, both the intermediate distance and the horizontal set-square adjustments of the mutually two wedges (10) are performed at the same time.

In Figure 5, it is illustrated that wedge (10) located wall cavity top edge, balance plate (11a) and main frame lateral profiles (2b) which is used as reference are covered in a manner that any cavity is prevented with the flat base. So the vertical intermediate distance adjustment is performed in this way.

In the Figure 6, it is illustrated that intermediary support profile (1) which is cut in consistent measures and assembled to the wall, main frame profile (2) and a main frame channel (3) embodied on the main frame profile (2) for providing movement of the hinge group (4) in the vertical direction upper and lower sense. The hinge group (4) comprises a door hinge (4a) and a channel hinge (4b) embodied in the main frame channel (3).

In the Figure 7, it is illustrated that intermediary support profile (1), main frame profile (2) are embodied the right and left sides of the wall cavity. Therefore, shifting the direction of the hinge group (4) by means of main frame channel (3) located right and left sides is possible. This entails the shifting of the direction of the lock bolt (5). This feature provides freedom of door opening direction.

Claims

1. An apparatus for embodying doorframe system in a wall (13) cavity comprising;

lower wedges (10) assembled to the wall (13) lateral and top surface,

an intermediary distance and set-square balance apparatus (11) for performing adjustment of intermediate distance and all planes before assembling the lower wedges (10) to the wall (13),

intermediary support profiles (1 ,1a) located on the lower wedges (10),

main frame profiles (2) located on the intermediary support profiles (1 ,1a)

2. An apparatus according to claim 1 , characterized in that a channel (3) embodied on the main frame profiles (2), and at least two channel hinge (4b) located along vertical direction in the said channel (3), and at least two door hinge (4a) located on door leaf.

3. An apparatus according to claim 2, characterized in that a door supporting mount (9) for preventing forcing of the channel (3) when bolt of the door lock positioned in the channel (3).

4. An apparatus according to claim 1 , characterized in that intermediary distance balance plate (1 1 a) embodied on the wedges (10) for performing and measuring plane adjustment of wedges (10) assembled to the wall (13), and one piece plumb line cord (1 1 e) contacted with the intermediary distance balance plate (1 1 a), and plumb line weight (1 1f) for providing the one piece plumb line cord (1 1 e) to downward direction so that performing adjustment of the wedges (10) at the same plane.

5. An apparatus according any one of the preceding claims, characterized in that the said lower wedges (10) having the shape of U comprising two short lateral surface and a long base surface.

6. An apparatus according any one of the preceding claims, characterized in that flare channel (10a) for preventing existence of bolt heads on the surface of the two lower lateral edges of the lower wedges (10) after screwing thereof.

7. An apparatus according any one of the preceding claims, characterized in that adjustment marks (10b) for calculating curvature of the wall (13) of the lower wedge (10).

8. An apparatus according any one of the preceding claims, characterized in that base form of the lower wedge (10) is in the same form of the intermediary support profile (1) that assembled on the lower edge (10).

9. An apparatus according any one of the preceding claims, characterized in that said intermediary support profile (1 ) located on the vertical surface of the wall cavity comprises a U-shaped upper side notches (6).

10. An apparatus according any one of the preceding claims, characterized in that said intermediary distance balance plate (11a) embodied on the wedge (10) comprises a plate holding hanger (11b).

11. An apparatus according any one of the preceding claims, characterized in that said main frame profile (2) located in the both vertical axis of the wall cavity and embodied on the intermediary profile (1 ) comprises channel (3) along the vertical axis, and two hinge group (4) for shifting door opening direction via the channels (3).

12. An apparatus according any one of the preceding claims, characterized in that said intermediary distance balance plate (11a) comprises profile holding channels (11c) for holding intermediary support upper head profile (1a).

13. An apparatus according any one of the preceding claims, characterized in that a vertical intermediary distance profile holding cavity (11d) embodied on the intermediary distance balance plate (11a) for adjusting intermediate distance.

14. An apparatus according any one of the preceding claims, characterized in that a set screw (8) for stretching and so squeezing the channel hinge (4b) placed on main frame profile channel (3).

15. An apparatus according any one of the preceding claims, characterized in that said door supporting mount (9) is being able to be positioned in the main frame channel (3) whereby the hinge group (4) is placed in reverse with respect to the door supporting mount (9).

16. An apparatus according any one of the preceding claims, characterized in that a standard system packet (12) for comprising the all apparatus in a cover bag.

17. A method for performing intermediate distance and set-square adjustment for doorframe systems comprising the following steps of;

putting wedges (10) and not fixing on the lateral and top sides of the door cavity that is present in the wall (13);

attaching the intermediary support upper head profile (1a) into the channels (11c) formed on the plates (1 1 a) in the adjustment apparatus (11 );

positioning/hanging the adjustment apparatus (1 1 ) to the mutual upper wedges (10) on said lateral wall sides thanks to the plate holding hanger (11 b);

balancing all wedges in two planes (x-y and x-z) thanks to the one piece cord system (11 e, 11f)) that is let from the positioned adjustment apparatus

(11 ) and measuring in one plane (y-z);

adjusting the horizontal intermediary distance thanks to said plates (11a) on the adjustment apparatus and the intermediary support upper head profiles (1a) utilized as a reference; adjusting the vertical intermediary distance thanks to one of said plates (11a) on the adjustment apparatus and the main frame side profiles utilized as a reference;

fixing wedges (10) having their entire balance performed to the wall (13) by tightening means such as screws;

removing the mechanism adjustment apparatus (11 ) from the assembly setting;

positioning the intermediary supporting frame (1 , 1a) on said wedges by a process of pressing and sliding; and

- positioning the main frame (2, 2a, 2b) on said intermediary supporting frame

(1 , 1a) such a way that for tolerating any possible inclination of the entire wall to inside or outside directions, the main frame (2, 2a, 2b) is placed inclined in an extent of plane adjustment unit measured (y-z) during performing (x-y and x-z) plane adjustments.

18. A method according to claim 17, characterized in that performing said perpendicular (x-y) balance by making the weight cords (11e) tangent with lower wedge (10) surfaces that represent on the lateral wall (13) surface during the setup step of said fixation system.

19. A method according to claim 17 and 18, characterized in that automatically transferring the horizontal adjustment performed on the most top wedges to the wedges on the lower level, by virtue of the adjustment apparatus (11) comprising a double lined, one piece cord (11e) with a certain weight (11f).

20. A method according to anyone of the claims 17 to 19, characterized in that performing the horizontal intermediary balance by removing the intermediary spaces of the intermediary support upper head profile (1a) that is utilized as a reference, of the balance plates (11a), and of the mutual upper plane wedges (10) on the lateral wall fronts.

21. A method according to anyone of the claims 17 to 20, characterized in that automatically realizing said horizontal set-square balance (x-z) as the end fronts of said elements (10, 11a, 1 a) are joined together.

22. A method according to anyone of the claims 17 to 20, characterized in that calculating the general curving amount of the entire wall (on the y-z plane) by the vertical reference traces on wedges and calculating curving amount of the entire wall by taking into account one line of the plumb line cord and the perpendicular traces on wedges positioned on the same side and then the trace number difference between the trace of the most upper level wedge wherefrom the plumb line cord is passed, and the trace of the wedge on the most lower level gives the curving amount of the entire wall and performing removal action of curving amount during assembling main frame profile (3) on the intermediary support profiles (1 ,1a).