PRIORITY APPLICATION DETAILS

[0001] The present application claims the priority from the Indian patent application number 202221060432 dated October 21, 2022, having a title as - A COMPOSITE COMPONENT AND USE THEREOF.

TECHNICAL FIELD

[0002] The present invention generally relates to the installation of doors and home decoration, in particular to an assembly structure of a door with an improved door/ window frame assembly.

BACKGROUND

[0003] The background information herein below relates to the present disclosure but is not necessarily prior art.

[0004] Conventionally, there are many types of doors used in daily life for different purposes including security doors, home doors etc. The door acts as an isolation space or a barrier at the entrance of a building or a room to be accessed. The mounting of doors in a building or for a house is a relatively time consuming and skilled task requiring specialist such as carpenters. The process of mounting of doors requires various different parts like frames, architrave and door jambs constituting a door assembly to be individually manufactured and used for installation of doors. Typically, the door components are made on site where required and usually require various adjustments to fit the particular door opening and the door to be hung therein, due to tolerances in the formation of door openings, especially in the thickness of the wall around the door opening and variations in the dimensions of doors themselves.

[0005] An assembly structure for an assembled door by improving the door and the door frame into an assembled structure ensuring that the door and the door frame are assembled on site and matches the door opening, ensuring service life and replacements to door decorations is provided. The original door that is assembled in the factory and cannot be adjusted in size is improved to an assembled door that can be assembled on site according to the size of the door opening, so that the door frame can be installed according to the size of the door opening, and the assembled door can also be installed according to the size of the door frame to ensure the door and the door frame.

[0006] For example, a Chinese patent application CN108 487 837 discloses about a door assembly structure. The state of the art discloses about a door assembly that can be used on a wider range of doorways providing a door installation assembly for a door frame including a sub-frame for supporting a door, a fixing means attachable to the door frame, and an attachment means for attaching the sub-frame to the fixing means, wherein the assembly is adapted to accommodate a variation in size between the door frame and the door is used. The sub-frame is designed to provide a new frame for the secondary door, and avoid the problems of having to fit the secondary door to the existing frame and the sub-frame may be custom-built, whereby dimensions of the existing door way are taken. This type of door assembly structure minimizes the need for highly detailed inspections and measurement prior to installation. But this type of assembly is only attachable to the surrounding wall, where a particular application of the invention requires a connection point away from the door frame, because of a damaged door frame, a considerably larger sub-frame being required.

[0007] Another example is an Australian Patent Application AU2000037765 which discloses a door installation assembly structure. The state of the art provides a conventional way of door installation assembly. The present state of the art focuses on dimensional inconsistencies between similar doors installed in a premises. Even where a number of identical doors are used, dimensional inconsistencies between individual doors mean that time consuming adjustments need to be made to the door frames during hanging of the doors also affecting the lifespan of the door assembly also due to excessive abrasion. Also, the decoration on the door cannot be replaced afterwards as will require the replacement of the whole door. The decorative trim around the doors that covers the seam between jamb and the wall known as an architrave also has a strong impact on the overall style, appearance, and proportion of the door opening and conceals the gap between the door jamb and the rough door opening and also helps to hold the frame in the opening. This architrave is installed individually requiring more time and providing no changes in decoration of the surface of architrave if needed afterwards. Such a type of door assembly adjustment is time consuming and usually involves planning or cutting of the frame components as per required.

[0008] Another example is provided in patent application GB2455859 which discloses different construction of architraves to be incorporated into the door assembly. The present state of the art states that the door and the door frame made on site by a skilled worker such as carpenter requires much more time to install and the size cannot be changed after installation is completed according to the field situation if required. Also, the skill level of carpenter makes a large difference in mounting precision of the door assembly also affecting the service life of the door frame. Also, different construction of architraves to be incorporated into the door assembly is done. A two part architrave section is used where at least one elongate door jamb portion and at least one elongate door stop securable to a face of at least one door jamb portion, wherein one of the architrave sections has a first part for laying contiguous with a first side surface of the door opening and a second part extending substantially perpendicular to said first part and being receivable within an elongate slot defined in or between a side of the respective door jamb portion to enable adjustment of the distance between the architrave sections.

[0009] To overcome all the disadvantages mentioned above and to provide a faster, more reliable door assembly with no dimensional inconsistencies whatsoever a multi-piece door assembly structure consisting of a door, door frame, jambs with architraves on a whole is assembled in a factory as a single unit and according to required dimensions is installed at the door wall is provided in the present claimed subject matter.

SUMMARY

[0010] Embodiments of the present claimed subject matter present technological improvements as solutions to one or more of the above- mentioned technical problems.

[0011] The present subject matter relating to a factory-made composite component used for a door frame and/or window frame thereof. The composite component may be a composite wooden component or all types of composite fiber board component, composite wood fiber component, composite plywood component, composite wood plastic component and/ or composite wood polymer component. In general meaning, whenever, the term "composite component" is referred in the present specification, the term can be referred alternatively as anyone or combination of more than one components listed above. It is to be understood that this application is not limited to the particular model or system described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure of the claimed subject matter. It is also to be understood that the terminology used in the description is for the purpose of describing the implementations or versions or embodiments only and is not intended to limit the scope of the present claimed subject matter.

[0012] This summary is provided to introduce aspects related to a factory- made composite component used for a door frame and/ or window frame and method thereof. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the present subject matter.

[0013] In one embodiment, a factory-made composite component is provided. The composite component is provided for used as a door frame and/or window frame. The composite component includes a base frame having two long members and one short member arranged in a manner to define an internal cavity. Each of the long member having a decorated surface; nondecorated surfaces and at least two openings for fixing. The short member having a decorated surface, non-decorated surface and at least two openings for fixing the short member with each of the long members with fastening mechanism such as glue or any other fastening agent. [0014] The composite component further includes at least two longer covering elements and a shorter covering element. Each of the longer covering element having a decorated surface and non-decorated surfaces. And, the shorter covering element is also having a decorated surface and non-decorated surface. Further, the composite component includes a plurality of gaskets which may a rubber gasket or another type of gasket made up of any other material widely used in the industry, wherein the gasket is arranged to be fitted on one or more slots provided on each of the longer covering elements and the shorter covering element. In another embodiment, each of the longer covering element and the shorter covering element with the decorated surface configured to be fitted on the non-decorated surface with the fastening mechanism such as glue or any other fastening agent resulted into a right-angle section to define a doorway and to fit a door.

[0015] In another embodiment, a factory-made composite component used for a door frame and/or window frame is provided. The composite component includes a base frame having two long members and one short member connected with a fastening agent such as glue on each edge of the long members and short member to define an internal cavity. The base frame is arranged to be fitted on a perfected wall with the fastening mechanism such as anchor fastener, nail, glue or any other fastening agent. Further, the composite component includes at least two longer covering elements and a shorter covering element configured to assemble along with the perfected wall to accommodate the width of the perfected wall and to be fitted with the help of fastening mechanism such as anchor fastener, nail, glue or any other fastening agent. Further, the two long members of the base frame from a non-decorated surface arranged to be fitted on to the perfected wall with the fasting mechanism. The short member of the base frame from a non-decorated surface configured to attach at right angle with two long members on top and to be fitted onto the perfected wall with fasting mechanism facing the non-decorated surface of the short member.

[0016] In another embodiment, each of the longer covering elements and the shorter covering element are different types of architraves with or without door jamb made up of one or different types of composite component.

[0017] In another embodiment, a method of fitting a factory-made door frame and/or window frame made up of composite component is provided. The method includes cutting, if required, at least two long members of a base frame according to the height of a perfected wall from the factory-made composite component, and cutting one short member of the base frame according to the width of the perfected wall made for a door installation. The method further includes the operation of joining, through the means of nails and/or glue and/ or any other fastening agent(s), two long members of a base frame with the edges of the short member of the base frame to make the base frame for the door installation. Further, the method includes the operation of fixing the assembled base frame on the outer surface adjacent to the perfected wall with fasting mechanism while keeping a decorated side of the base frame facing outside, and cutting, if required, at least two longer covering elements according to the height of the base frame. The method further includes cutting a shorter covering element according to the width of the base frame, and fitting one or more gaskets into one or more longitudinal slots provided on each of the longer covering elements and the shorter covering element resulting into a configuration for the door installation. Further, the method includes the operation of applying glue or any other fastening agent(s) on non-decorated surface of inner surface of the base frame. The method further includes applying glue or any other fastening agent(s) on inner surfaces of each of the longer covering elements and on inner surface of the shorter covering element. Further, the method includes the operation of fitting each of the longer covering elements and the shorter covering element onto the perfected wall. Wherein the fitting the shorter covering element onto the perfected wall in such a manner that the shorter covering element hold and cover the top-front side of the perfected wall as well as inner upper side of the base frame. In another embodiment, wherein the fitting each of the longer covering elements onto the perfected wall in such a manner that the each of the longer covering elements hold and cover the side-front of the perfected wall as well as inner side of the base frame.

BRIEF DESCRIPTION OF ACCOMPANYING DRAWING

[0018] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure; however, the disclosure is not limited to the specific system or method disclosed in the document and the drawings.

[0019] The present disclosure is described in detail with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer various features of the present subject matter. [0020] Figure 1A illustrates a profile of door frame and/or window frame made up of the composite component, in accordance with an embodiment of the present disclosure.

[0021] Figure IB illustrates a side view of the door frame and/or window frame made up of the composite component, in accordance with an embodiment of the present disclosure.

[0022] Figure 2A illustrates a back view of the short member of a base frame of the door, in accordance with an embodiment of the present disclosure.

[0023] Figure 2AA illustrates a front view of the short member of a base frame of the door, in accordance with an embodiment of the present disclosure.

[0024] Figure 2B illustrates a front view of the one of the long members of a base frame of the door, in accordance with an embodiment of the present disclosure.

[0025] Figure 2C illustrates a back view of the one of the long members of a base frame of the door, in accordance with an embodiment of the present disclosure.

[0026] Figure 2D illustrates a front view of the complete base frame of the door, in accordance with an embodiment of the present disclosure.

[0027] Figure 2E illustrates a back view of the complete base frame of the door, in accordance with an embodiment of the present disclosure.

[0028] Figure 3A illustrates a front view of the shorter covering element of the door, in accordance with an embodiment of the present disclosure. [0029] Figure 3B illustrates a back view of the shorter covering element of the door, in accordance with an embodiment of the present disclosure.

[0030] Figure 3C illustrates a front view of the one of the two longer covering elements of the door, in accordance with an embodiment of the present disclosure.

[0031] Figure 3D illustrates a back view of the one of the two longer covering elements of the door, in accordance with an embodiment of the present disclosure.

[0032] Figure 4 illustrates an exploded view of the complete assembled door with the door frame and/or window frame made up of the composite component, in accordance with an embodiment of the present disclosure.

[0033] In the above accompanying drawings, a non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.

DETAILED DESCRIPTION

[0034] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising," "having," "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Although a factory -made composite component used for a door frame and/ or window frame and method of manufacturing thereof, similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, a factory-made composite component used for a door frame and/or window frame and method of manufacturing thereof is now described.

[0035] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. For example, although the present disclosure of the claimed subject matter will be described in the context of a factory-made composite component used for a door frame and/ or window frame and method of manufacturing thereof, one of ordinary skill in the art will readily recognize a factory-made composite component used for a door frame and/ or window frame and method of manufacturing thereof can be utilized in any situation. Thus, the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.

[0036] In one embodiment, a method of fitting a factory-made door frame and/or window frame made up of composite component is provided. The method includes cutting, if required, at least two long members of a base frame according to the height of a perfected wall from the factory-made composite component, and cutting one short member of the base frame according to the width of the perfected wall made for a door installation. The method further includes the operation of joining, through the means of nails and/or glue and/ or any other fastening agent(s), two long members of a base frame with the edges of the short member of the base frame to make the base frame for the door installation. Further, the method includes the operation of fixing the assembled base frame on the outer surface adjacent to the perfected wall with fasting mechanism while keeping a decorated side of the base frame facing outside, and cutting, if required, at least two longer covering elements according to the height of the base frame. The method further includes cutting a shorter covering element according to the width of the base frame, and fitting one or more gaskets into one or more longitudinal slots provided on each of the longer covering elements and the shorter covering element resulting into a configuration for the door installation.

[0037] Further, the method includes the operation of applying glue or any other fastening agent(s) on non-decorated surface of inner surface of the base frame. The method further includes applying glue or any other fastening agent(s) on inner surfaces of each of the longer covering elements and on inner surface of the shorter covering element. Further, the method includes the operation of fitting each of the longer covering elements and the shorter covering element onto the perfected wall. Wherein the fitting the shorter covering element onto the perfected wall in such a manner that the shorter covering element hold and cover the top-front side of the perfected wall as well as inner upper side of the base frame. In another embodiment, wherein the fitting each of the longer covering elements onto the perfected wall in such a manner that the each of the longer covering elements hold and cover the sidefront of the perfected wall as well as inner side of the base frame.

[0038] In another embodiment, a factory-made composite component is disclosed. The composite component is provided for used as a door frame and/or window frame. The composite component includes a base frame having two long members and one short member arranged in a manner to define an internal cavity. Each of the long member having a decorated surface; non-decorated surfaces and at least two openings for fixing. The short member having a decorated surface, non-decorated surface and at least two openings for fixing the short member with each of the long members with fastening mechanism such as glue or any other fastening agent. The composite component further includes at least two longer covering elements and a shorter covering element. Each of the longer covering element having a decorated surface and non-decorated surfaces. And, the shorter covering element is also having a decorated surface and non-decorated surface. Further, the composite component includes a plurality of gaskets such as rubber gaskets or gaskets made of any other materials which is industrially viable, wherein the gasket is arranged to be fitted on one or more slots provided on each of the longer covering elements and the shorter covering element. In another embodiment, each of the longer covering element and the shorter covering element with the decorated surface configured to be fitted on the non-decorated surface with the fastening mechanism such as glue or any other fastening agent resulted into a right-angle section to define a doorway and to fit a door.

[0039] In another embodiment, a factory-made composite component used for a door frame and/or window frame is disclosed. The composite component includes a base frame having two long members and one short member connected with a fastening agent such as glue on each edge of the long members and short member to define an internal cavity. The base frame is arranged to be fitted on a perfected wall with the fastening mechanism anchor fastener, nail, glue or any other fastening agent. Further, the composite component includes at least two longer covering elements and a shorter covering element configured to assemble along with the perfected wall to accommodate the width of the perfected wall and to be fitted with the help of fastening mechanism such as anchor fastener, nail, glue or any other fastening agent. Further, the two long members of the base frame from a non-decorated surface arranged to be fitted on to the perfected wall with the fasting mechanism. The short member of the base frame from a non-decorated surface configured to attach at right angle with two long members on top and to be fitted onto the perfected wall with fasting mechanism facing the non-decorated surface of the short member.

[0040] In another embodiment, each of the longer covering elements and the shorter covering element are different types of architraves with or without door jamb made up of one or different types of composite component.

[0041] Figure 1A illustrates a profile of door frame and/or window frame made up of the composite component, in accordance with an embodiment of the present disclosure.

[0042] In an embodiment, the profile of door frame and/ or window frame 100 is provided. The profile of door frame and/ or window frame illustrates a base frame 200. The base frame 200 having at least two long members 201 (201A, 201B) and one short member 205 arranged in a manner to define an internal cavity. The base frame 200 is connected with a short covering element 303 which can also be referred as front covering element. The base frame 200 is connected with longer covering element(s) 301 (301A, 301B). The base frame 200, short covering element 303 and longer covering elements 301 having a decorated outer surface 110, such as laminated surface or veneered surface or any other type of decorated surface with leading industrially viable solution. Other examples of decorated surface may include PVC surface, acrylic surface, paint surface, paper surface, glass surface, print surface, fibre surface and the like. Further, the base frame 200, short covering element 303 and longer covering elements 301 also have a decorated surface 120 such as a PVC edge banding surface and the like.

[0043] Figure IB illustrates a side view 100 of the door frame and/ or window frame made up of the composite component, in accordance with an embodiment of the present disclosure. The base frame 200 and the covering element(s) 300 are arranged at the right angle as shown in 102, i.e., 90-degree angle between them. The covering element(s) 300 has the rebate. The 90-degree angle between the base frame 200 and the covering element(s) 300 is indicated by 104 in figure IB.

[0044] Figure 2A illustrates a back view and Figure 2AA illustrates a front view of the short member 205 of a base frame 200 of the door, in accordance with an embodiment of the present disclosure.

[0045] The short member 205 is having a decorated surface 204, non-decorated surface 202, 206 & 208 and at least two openings 210 A and 210B for fixing the short member 205 with each of the long members (not shown in figure) with fastening mechanism. The decorated surface 204 can be laminated surface or veneered surface or any other type of decorated surface with leading industrially viable solution.

[0046] Figure 2B illustrates a front view of the one of the long members 201A of a base frame 200 of the door, in accordance with an embodiment of the present disclosure. [0047] The long member 201A is having a decorated surface 204 and a nondecorated surface 206 and at least two openings 210A and 210B for fixing the long member 201A with the short member (not shown in figure). The decorated surface 204 can be laminated surface or veneered surface or any other type of decorated surface with leading industrially viable solution.

[0048] Figure 2C illustrates a back view of the one of the long members 201B of a base frame 200 of the door, in accordance with an embodiment of the present disclosure.

[0049] The long member 201B is having a non-decorated surfaces 202, 208 and at least two openings 210A and 210B for fixing the long member 201B with the short member (not shown in figure).

[0050] Figure 2D illustrates a front view of the complete base frame 200 of the door and Figure 2E illustrates a back view of the complete base frame 200 of the door, in accordance with an embodiment of the present disclosure.

[0051] The base frame 200 is having at least two long members 201 A, 201B and one short member 205 arranged in a manner to define an internal cavity. Each of the long member 201A, 201B is having a decorated surface 204; and nondecorated surfaces 202, 206, 208 and at least two openings 210A, 210B for fixing the long members with the short member to form a complete base frame 200.

[0052] Figure 3A illustrates a front view and Figure 3B illustrates a back view of the shorter covering element 303 of the door, in accordance with an embodiment of the present disclosure.

[0053] The shorter covering element 303 is having a decorated surface 302 and non-decorated surfaces 304A, 304B. The shorter covering element 303 includes one or more gasket(s) 308 such as rubber gasket, wherein the gasket 308 is arranged to be fitted on one or more slots 306 provided on the shorter covering element 303. Further, the shorter covering element 303 has a slotted surface side 310 adjacent to edge of the slot 306.

[0054] Figure 3C illustrates a front view and Figure 3D illustrates a back view of the one of the two longer covering elements 301A, 301B of the door, in accordance with an embodiment of the present disclosure.

[0055] Each of the longer covering elements 301 A, 301B are having a decorated surface 302 and non-decorated surfaces 304A, 304B. The longer covering elements 301A, 301B includes one or more gasket(s) 308 such as rubber gasket, wherein the gasket 308 is arranged to be fitted on one or more slots 306 provided on the longer covering elements 301A, 301B. Further, each of the longer covering elements 301A, 301B and a shorter covering element 303 are configured to assemble onto to the base frame 200to accommodate the width of the perfected wall 500 and to be fitted with the help of fastening mechanism anchor fastener, nail, glue or any other fastening agent. Further, the each of the longer covering elements 301 A, 301B have a slotted surface side 310 adjacent to edge of the slot 306.

[0056] Furthermore, the each of the two longer covering elements 301A, 301B and the shorter covering element 303 are attached onto the base frame 200 in such a manner to cover any gap in between the perfected wall 500 and the base frame 200.

[0057] Figure 4 illustrates an exploded view of the complete assembled door with the door frame and/or window frame made up of the composite component, in accordance with an embodiment of the present disclosure. [0058] A method of fitting a factory -made door frame and/ or window frame made up of composite component 100 can be described while referring to Figure 4. The method of fitting a factory-made door frame and/ or window frame made up of composite component 100 includes cutting at least two long members 201 A, 201B of a base frame 200 according to the height of a perfected wall 500 from the factory-made composite component 100. The method further includes cutting one short member 205 of the base frame 200 according to the width of the perfected wall 500 made for a door shutter 410 installation, and joining, through the means of nails 420 and/or glue and/or anchor fastener 440 and/or with any other fastening mechanism, two long members 201 A, 201B of a base frame 200 with the edges of the short member 205 of the base frame 200 to make the base frame 200 for the door installation.

[0059] The method further includes fixing the assembled base frame 200 on the outer surface adjacent to the perfected wall 500 with fasting mechanism 440 while keeping a decorated side 204 of the base frame 200 facing outside. Further, the method involves cutting at least two longer covering elements 301 A, 301B according to the height of the base frame 200, and cutting a shorter covering element 303 according to the width of the base frame 200. Further, the method includes fitting one or more gaskets 308 into one or more longitudinal slots 306 provided on each of the longer covering elements 301 A, 301B and the shorter covering element 303 resulting into a configuration for the door shutter 410 installation. Further, the method provides applying glue on non-decorated surfaces 206 of inner surface of the base frame 200 and applying glue or any other fastening agents on inner surfaces 304A, 304B of each of the longer covering elements 301A, 301B. Further, the method includes applying glue on inner surface 304A, 304B of the shorter covering element 303 and fitting each of the longer covering elements 301 A, 301B and the shorter covering element 303 onto the base frame 200.

[0060] The method further provides the fitting of the shorter covering element 303 onto the base frame 200 in such a manner that the shorter covering element hold and cover the top-front side of the perfected wall 500 as well as inner upper side of the base frame 200, and the fitting each of the longer covering elements 301 A, 301B onto the base frame 200 in such a manner that the each of the longer covering elements 301A, 301B hold and cover the side-front of the perfected wall 500 as well as inner side of the base frame 200. Figure 4 also provides the installation of door shutter 410 onto the base frame 200. The door shutter 410 is installed by fixing it with base frame 200 with the help of hinges 430.