US3400490A - Pocket door assembly - Google Patents

Description

P 1968 R. F. ANDERSON POCKET DOOR ASSEMBLY 3 Sheets-Sheet 1 Filed Oct. 14, 1966 I I\ I\\\ p 10, 1968 R. F. ANDERSON POCKET DOOR ASSEMBLY 3 Sheets-Sheet 2 Filed Oct. 14, 1966 P 8 R. F. ANDERSON 3,400,490

POCKET DOOR ASSEMBLY Filed Oct. 14, 1966 3 Sheets-Sheet 5 United States Patent 3,400,490 POCKET DOOR ASSEMBLY Ralph F. Anderson, Rockford, Ill., assignor to National Lock Co., Rockford, 111., a corporation of Delaware Filed Oct. 14, 1966, Ser. No. 586,867 4 Claims. (Cl. 49-372) ABSTRACT OF THE DISCLOSURE A sliding door assembly where the door slides into and out of a pocket formed in the adjacent wall supported on an overhead track and having a rough frame for the doorway and pocket including a horizontal bridging member between vertical frame members defining the inner end of the pocket and the outer edge of the door opening; and the overhead elongated door track is secured to hangers which are in turn secured to the bridging member. The track includes a horizontal flat plate having a central depending elongated J-shaped track and depending parallel flanges spaced from the track to position nailing strips above the door opening. Vertical split studs formed of metal with wood inserts defining the pocket opening for the door are secured at their upper ends to the bridging member and at their lower ends to the floor; the studs terminating at their lower ends in inturned flanges having irregular nesting peripheries. The door is mounted on a pair of hanger brackets carrying rollers riding in the J- shaped track, the brackets having depending flanges secured to the face of the door adjacent the upper edge; and one bracket has a plastic adjusting wheel in a lower bracket portion cooperating with a depending adjusting screw having a thread cutting end mounted on the upper hanger racket portion for adjustment of the door in the opening therefor.

The present invention relates to a pocket door assembly and more particularly to a sliding door assembly where a sliding door is movable into and out of a side pocket provided in the wall adjacent the frame of the door.

Among the objects of the present invention is the provision of a sliding door movable into a side pocket in a wall adjacent the door frame which is easily and simply removed and replaced in the case of warpage or damage without the necessity of removal of trim boards of the door frame. The door is provided with a pair of top roller bracket assemblies, one being vertically adjustable, which are mounted on the same surface of the door. Removing the fastening screws of these brackets allows the door to be swivelled in the door opening without removing the brackets from the overhead track.

Another object of the present invention is the provision of a sliding door assembly having adjustable pairs of vertical split studs in and defining the pocket receiving the door. The split stud is designed with a self-adjusting feature at the floor mounting area so that proper clearance is obtained for the door operation. When the two studs are nailed into position, the bottom of each stud is provided with an inwardly extending flange with the shape of the flange allowing nesting to assure the necessary opening between the two studs.

A further object of the present invention is the provision of a sliding door assembly movable into a side pocket having split studs, and plastic guides for the door provided on the studs. The guides are applied after the trim strips have been secured to define the door frame making it very easy to determine the proper door guidance for its travel in and out of the pocket.

The present invention also comprehends the provision of a sliding door assembly cooperating with a side pocket where the door is hung on a pair of roller brackets; one

bracket being vertically adjustable. The bracket is provided with a depending adjusting screw on a roller bracket portion and an adjusting or gear type wheel on the door bracket portion. The adjusting screw is of the thread cutting type which cuts a thread in the plastic adjusting wheel assuring a tight fit therebetween to maintain any desired adjustment.

Further objects are to provide a construction of maximum simplicity, etficiency, economy and ease of assembly and operation, and such further objects, advantages and capabilities as will later more fully appear and are inherently possessed thereby.

In the drawings:

FIGURE 1 is a side elevation-a1 view partly in cross section showing the sliding door in a door frame and the adjacent wall forming the pocket for the door.

FIG. 2 is an enlarged and broken vertical cross sectional view taken on the line 22 of FIG. 1.

FIG. 3 is a broken side elevational view of the door and pocket hardware with the door frame and wall omitted.

FIG. 4 is a partial enlarged top plan view of the door track.

FIG. 5 is an end elevational view of the door track.

FIG. 6 is a front elevational view of the rear door hanger bracket.

FIG. 7 is an end elevational view of the bracket of FIG. 6.

FIG. 8 is a side elevational view of the adjustable front hanger bracket.

FIG. 9 is an end elevational view of the bracket of FIG. 8.

FIG. 10 is a horizontal cross sectional view taken on the line 10-10 of FIG. 9.

FIG. 11 is a broken perspective view of a pair of split studs for the pocket.

Referring more particularly to the disclosure in the drawings wherein is shown an illustrative embodiment of the present invention, FIG. 1 discloses a sliding door 10 adapted to provide a closure for a door frame 11 in a wall 12; the wall containing a pocket 13 to receive the door 10 when it is withdrawn or retracted to provide access between rooms through the door frame 11. The door frame 11 includes a basic frame formed of a vertical frame member 14 opposite the pocket, and a horizontal bridging wood insert 15 extending between the frame member 14 and the vertical stud 16 defining the closed end of the pocket.

Secured to the bridging wood insert 15 are a plurality of spaced U-shaped brackets 17 each having a base portion 18 with a pair of openings 19 and spaced vertical arms 21, 21 having openings 22 for suitable securing means 23 to secure the arms 21 to the sides of the insert 15. Mounted below the insert 15 and brackets 17 is a horizontal extruded aluminum door track 24 including a generally flat member or plate 25 having spaced openings 26 adjacent each edge, depending parallel flanges 27 and a generally centrally located depending track 28 of a generally J-shape; the flanges 27 being spaced inwardly from the edges of the flat plate member 25.

Wood strips 29 are supplied with the pocket door hardware and are positioned in the area defined by the top flat member 25 and the flanges 27 as shown in FIG. 2. Suitable securing means such as screws 31 are inserted downwardly through the openings 19 and threadingly engage the aligned openings 26 by the use of Tinnerman fasteners or the like to support the door track 24 and, in the door frame 11, the screws 31 extend through the openings 26 into and threadingly engage and secure the wood strips 29 in proper position at the top of the door frame. Both the wood strips 29 and the door track 24 are marked at suitable intervals, such as 2-inch increments, to provide a gauge of the cut-off points for varying dimensions of door frame 11 (see FIGS. 3 and 4). Thus, the hardware and wood strips 29 are supplied in a standard length and are cut down to the desire-d size at the job site by the workmen when the door frame and pocket are installed.

To properly define the pocket in the wall and guide the door during opening and closing movement, pairs of vertical split studs 33 are located to define the path of movement of the door in the pockets; the studs being formed of metal and having elongated wood inserts 34 therein with the wood inserts of generally T-shape in cross section with the leg 35 projecting outwardly from one side. The split studs 33 each include a back wall 36 with opposed side walls 37 having elongated slots 38 at spaced intervals. The side walls 37 terminate in inturned flanges 39 to form a conforming enclosure for the wood inserts 34; the leg 35 thereof extending outwardly between the flanges 39.

At the upper end of each stud 33, the back wall 36 is bent over the side walls 37 as at 41 and then upwardly to form a vertical offset flange 42 having openings 43 to receive suitable securing means to secure the flange 42 to the bridging wood insert 15. At the lower end of the back wall 36 is provided an inturned flange 44 having an irregular nesting outer edge 45 and openings 46 for suitable securing means such as nails 47 to secure the flange to the floor 48 below the pocket. The flanges 44 of a pair of opposed split studs 33 are of such length as to nest together to assure the necessary opening between the two studs for movement of the door 10.

To allow movement of the door into and out of the pocket, the door is provided with front and rear hanger bracket assemblies having rollers which move in the depending track 28 of the door track 24. The front bracket assembly 49 (FIGS. 8 to 10) includes a front bracket 51 having a vertical mounting portion 52 with openings 53 for suitable securing means, such as screws 54, to secure the bracket to the door 10. A horizontal portion 55 is formed at right angles to the vertical portion over the top edge 56 of the door 10 and spaced from the top edge by depending ears 57 integral with the horizontal portion 55. The portion 55 is provided with a centrally positioned enlarged opening 58 for an adjusting wheel 61, and reinforcing ribs 59 are formed at the juncture of the vertical and horizontal portions 52, 55.

The adjusting wheel 61 has a central hub 62 defining a central opening 63 and a fluted or toothed periphery 64 for ease of adjustment. The wheel 61 is positioned between the horizontal portion 55 of bracket 51 and the top edge 56 of the door with the central hub 62 extending into the opening 58 in the horizontal portion 55 of bracket 51 to provide an axis of rotation for the wheel. Aligned with the opening 58 in the horizontal portion 55 is an opening 65 into the top edge 56 of the door 10.

The front bracket assembly 49 further includes a front hanger bracket 66 having a horizontal flange 67 with a central opening 69 adapted to receive an adjusting screw 71 having a thread cutting lower end 72, threaded shank 73 and a cylindrical end 74 with a radial flange 75. The smooth cylindrical end 74 is inserted into the opening 69 with the flange 75 positioned below the horizontal flange '67 of the bracket 66, and the portion of the end 74 extending above the flange 67 being staked onto the flange. The cutting end 72 enters the opening 63 in the wheel 61 and cuts threads into and is in threaded engagement with the adjusting wheel and extends downward into the opening 65 in the door. The wheel 61 is formed of a suitable relatively soft material, such as nylon, which will allow for ease of cutting the threads thereinto.

A vertical flange 76 of the bracket 66 has an offset upper portion with a central opening 77 for a roller rivet 78 carrying a roller 79 which rolls in the generally 1- shaped track 28 as seen in FIG. 2. Reinforcing ribs 81 are provided at the juncture of the horizontal and vertical flanges 67 and 76, respectively. It can be seen that rotation of the adjusting wheel 61 relative to the adjusting screw 71 will provide vertical adjustment of the distance between the door bracket 51 and the hanger bracket 66.

The rear bracket assembly 82 (FIGS. 6 and 7) includes a vertical mounting portion 83 having openings 84 for suitable securing means, a horizontal portion or ledge 85 adapted to contact the upper edge 56 of the door 10, and a vertical upper flange or portion 86 having an offset upper end 87 with an opening 88 therein. The opening 88 receives a roller rivet 89 carrying a second roller 90 moving in the depending track 28. A strengthening or reinforcing rib 91 is formed at the juncture of the horizontal portion 84- and the upper portion 85.

When the bracket 17 and door track 24 have been installed on the bridging wood insert 15 and the split studs 33 have been secured to the insert 15 and the floor 48 through the flanges 42 and 44, front and rear bracket assemblies 49 and 82 are installed on the door 10 and hung on the track 28 to hang the door 10 in position. A resilient bumper 92 is secured to the vertical stud 16 to cushion movement of the door 10 into the pocket 13. Then horizontal wood trim strips 93 are secured to the underside of wood strips 29 and vertical wood trim strips 94 are positioned abutting the split studs 33 forming the edge of the pocket. Then dry wall 95 can be applied and finished to form the wall around the door frame 11 and covering and enclosing the pocket 13, and the wood moulding strips 96 around the frame 11 and the base moulding strips 97 and quarter round or other edging strips 98 applied at the base of the wall as seen in FIG. 1. Also right angle bottom door guides 99 having a mounting opening 101 in each face can be secured to the trim strips 94 by suitable securing means, such as screws 102, to guide the movement of the lower portion of the door 19.

As seen in FIGS. 1 and 2, the openings 84 in the rear bracket assembly 82 and the openings 53 on the front door bracket 51 are all exposed below the trim strips 93 so that the screws can be removed and the door taken out of the frame 11 without removal of any trim boards. Thus replacement of the door 10 because of warpage or damage thereto is easily effected. Also, access may easily be obtained to the adjusting wheel by a screwdriver or other narrow tool with the door 10 in open position to adjust the position of the door. As adjustments are normally minor, only the front bracket assembly 49 is made adjustable. The plastic wheel 61 and cutting adjustment screw 71 provide a tight fit for positive holding in an adjusted position. Further, the guides 99 are applied after the trim strips 94 are installed making it easy to apply the guides for determining the proper door guidance for its travel.

Having thus disclosed the invention, I claim:

1. A sliding door assembly mounted in a door frame for reciprocation into and out of a pocket formed in the adjacent wall, comprising an elongated track horizontally extending within the door frame and the pocket in the adjacent wall and including a relatively wide flat elongated plate having a central depending and longitudinally extending J-shaped track and a pair of elongated depending flanges parallel to and spaced from said J-shaped track and spaced inwardly from the longitudinal edges of the plate, a plurality of U-shaped brackets removably secured to and supporting said track plate, a sliding door adapted to close the opening defined by the door frame, an adjustable front hanger bracket assembly and a rear hanger bracket, each having a horizontal flange parallel to the upper edge of the door and a depending mounting flange secured to a face of the door, both said front hanger bracket assembly and said rear hanger bracket each carrying a roller at its upper end riding in said J-shaped track, wood nailing strips adapted to be located abutting the lower surface of said track plate and the outer surface of a depending flange of the track, said wood strips being secured to said track plate, at least one pair of opposed split studs defining the wall pocket and having a generally channel shape, a wood insert for each of said split studs, each stud having a vertical mounting flange at the upper end and an inwardly extending horizontal flange at the lower end thereof secured to the floor, and a bridging wood insert defining the upper surface of the door opening and pocket, said upper flanges of the split studs and said U-shaped brackets being secured to said bridging insert.

2. A sliding door assembly as set forth in claim 1, in which said elongated track and said wood nailing strips are marked at intervals to provide cut-off points therefor for varying door and frame dimensions.

3. A sliding door assembly as set forth in claim 1, in which said lower horizontal flanges on said split studs have identical irregular peripheries which, when one is reversed and facing the other, are complementary and adjustably nest together.

4. A sliding door assembly as set forth in claim 1, in which said adjustable front hanger bracket assembly includes a door bracket having said vertical mounting flange and said horizontal flange having a central opening therein, a pair of depending ears on said horizontal flange abutting the top edge of the door and spacing said horizontal flange thereabove, a plastic adjusting wheel having a fluted periphery positioned between the top edge of the door and the horizontal flange and having a central hub extending into the central opening in said horizontal flange, said wheel and hub having a passage extending axially therethrough, and a front hanger bracket carrying said roller at the upper end thereof and having a horizontal flange at its lower end and a depending adjusting screw staked in said last mentioned horizontal flange and having a thread-cutting lower end such that said screw cuts the threads in the axial passage in the adjusting wheel to provide a positive retaining engagement therebetween in any adjusted position, said door having an opening in the top edge aligned with the passage in the adjusting wheel to receive the depending end of said adjusting screw.

References Cited UNITED STATES PATENTS 2,761,172 9/1956 Jorgensen et al 16-105 2,818,608 1/1958 Lawrence 49-372 XR 3,058,174 10/1962 Sterling 49-372 KENNETH DOWNEY, Primary Examiner.

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