Description:TECHNICAL FIELD
[0001] The present disclosure relates generally to the field of door frames and shutters. In particular, the present disclosure relates to a lightweight, strong, and durable door frame and door/shutter, which are warpage free, resistant to fire, corrosion, water, and fire, and provide an aesthetic wooden appearance. Further, the present disclosure relates to a method for manufacturing a lightweight, strong, and durable door frame and door/shutter.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] Door frames and doors are essential components of any building structure. Door frames provides support and stability to the doors or shutters of the building, as well as to hold the doors or shutters in place. The door frame serves as the structural framework for the door or shutter, providing a secure and stable base for the hinges, latches, and guide rails to attach to.
[0004] Over the years, door frames and doors have been subject to various improvements and modifications to enhance their durability and functionality. For instance, traditional door frames and doors made of wood was susceptible to warping, cracking, rotting, termites, and fire. As a result, newer materials such as polyvinyl chloride (PVC), fiberglass, concrete, and aluminum have been introduced to overcome the termite, wrapping, and rotting issues associated with wooden door frames and doors for improving their longevity. However, these non-wooden materials used in door frames are not strong enough to withstand the load of heavy doors or shutters and are also difficult to fixed in the building structure. In addition, these non-wooden materials are still susceptible to fire, cracking, and deformation under unfavorable conditions, making them unsuitable and prone to failure in the longer run. Moreover, these materials fail to provide the aesthetic woody appearance and texture provided by traditional wooden frames and doors.
[0005] There is, therefore, a requirement in the art for a means to overcome the above drawbacks, shortcomings, and limitations associated with existing door frames and doors, and to design and develop a light-weight, strong, and durable door frame and door that are warpage free, resistant to fire, corrosion, water, and fire, and which also provide an aesthetic woody appearance and texture.

OBJECTS OF THE PRESENT DISCLOSURE
[0006] Some of the objects of the present disclosure, which at least one embodiment herein satisfy are as listed hereinbelow.
[0007] It is an object of the present disclosure to overcome the above-mentioned drawbacks, shortcomings, and limitations associated with existing door frames and doors.
[0008] It is an object of the present disclosure to provide a lightweight, strong, and durable door frame and doors for buildings and structures.
[0009] It is an object of the present disclosure to protect door frames and doors from warpage, fire, corrosion, water, and fire and increase their longevity.
[0010] It is an object of the present disclosure to provide a lightweight, strong, and durable door frame and door, that has an aesthetic woody appearance and texture.
[0011] It is an object of the present disclosure to lower the usage of wood in door frames and doors while still providing strength and the aesthetic woody appearance and texture.
[0012] It is an object of the present disclosure to provide a lightweight, strong, and durable door frame that is warpage free, resistant to fire, corrosion, water, and fire, and also provides an aesthetic woody appearance and texture.
[0013] It is an object of the present disclosure to provide a lightweight, strong, and durable door that is warpage free, resistant to fire, corrosion, water, and fire, and provides an aesthetic woody appearance and texture.
[0014] It is an object of the present disclosure to provide a method for manufacturing a lightweight, strong, and durable door frame that is warpage free, resistant to fire, corrosion, water, and fire, and has an aesthetic woody appearance and texture.

SUMMARY
[0015] The present disclosure relates to a lightweight, strong, and durable door frame and door/shutter, which are warpage free, resistant to fire, corrosion, water, and fire, and provide an aesthetic wooden appearance. Further, the present disclosure relates to a method for manufacturing a lightweight, strong, and durable door frame and door/shutter.
[0016] According to an aspect, a method for manufacturing a door frame is disclosed. The method comprises the steps of fabricating a sheet of a first material in a predefined shape to form a first member defining a shape of the door frame, and attaching one or more sections of wood, having first predefined dimensions based on a dimension of one or more sides of the first member and the shape of the door frame, to the one or more sides of the first member to form the door frame.
[0017] In an aspect, the method of fabricating the sheet into the first member may comprise the steps of bending and/or cut-pressing the sheet in one or more second sections having second predefined dimensions, and welding the one or more cut-pressed sheet sections using the first material to form the first member having the predefined shape.
[0018] In an aspect, the method may comprise the steps of welding one or more flat plates at predefined locations on the first member and fitting one or more anchor fasteners on the one or more first plates, and welding one or more pre-drilled and tapped pads on the first member, wherein each of the pads is adapted to receive and engage a hinge screw therewithin.
[0019] In an aspect, the method may comprise the steps of forming at least one cut-out in the first member and providing a back cover on the corresponding the cut-out, wherein the cut-out is adapted to accommodate at least a portion of a door lock therein.
[0020] In an aspect, the method may comprise the steps of polishing the one or more wood sections, applying glue on one or more sides of each of the polished wood sections such that at least one of the sides remains unglued, heat-pressing a veneer on the glued sides of the polished wood sections to coat the veneer on the glued sides of the wood sections, and attaching the unglued side of the veneer-coated wood sections on the one or more sides of the first member to form the door frame.
[0021] In an aspect, the method may comprise the steps of polishing the formed door frame and coating the polished door frame with polyurethane.
[0022] In an aspect, the first material may be galvanized steel.
[0023] According to another aspect, a door frame and a door assembly is disclosed. The assembly comprises a door frame adapted to be coupled to a structure. The door frame comprises a first member having a first predefined shape defining a shape of the door frame, wherein the first member is fabricated from a sheet of galvanized steel, and one or more first wood sections, having dimensions based on a dimension of one or more sides of the first member and the shape of the door frame, attached on the one or more sides of the first member.
[0024] In an aspect, the assembly comprises a door adapted to be movably coupled to the door frame. The door comprises a second member having a second predefined shape defining a shape of the door, wherein the second member may be fabricated from a sheet of galvanized steel. Further, the door comprises one or more second wood sections, having dimensions based on a dimension of one or more sides of the second member and the shape of the door, attached to the one or more sides of the second member.
[0025] In an aspect, the door frame may comprise one or more flat plates welded at predefined locations on the first member, one or more anchor fasteners fitted on the one or more first plates, and one or more predrilled and tapped pads provided on the first member, wherein each of the pads is adapted to receive and engage a hinge screw therewithin.
[0026] In an aspect, the door frame, and the door may comprise at least one cut-out adapted to accommodate at least a portion of a door lock therein.
[0027] In an aspect, the door frame may comprise a veneer coated on at least one side of the one or more first wood sections of the door frame, wherein a non-veneer side of the veneer-coated first wood section is attached to the one or more sides of the first member to form the door frame. In addition, a veneer may also be coated on at least one side of the one or more second wood sections of the door, wherein a non-veneer side of the veneer-coated second wood section is attached to the one or more sides of the member to form the door.
[0028] Various objects, features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent features.
[0029] Within the scope of this application, it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible

BRIEF DESCRIPTION OF DRAWINGS
[0030] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and, together with the description,
[0031] FIG. 1 illustrates exemplary steps involved in the proposed method for manufacturing a door frame, in accordance with an embodiment of the present disclosure.
[0032] FIG. 2A illustrates an exemplary view of the proposed door frame, in accordance with an embodiment of the present disclosure.
[0033] FIG. 2B illustrates an exemplary view of the fabricated first member of the proposed door frame of FIG. 2A, in accordance with an embodiment of the present disclosure.
[0034] FIG. 2C illustrates an exemplary view of the veneer-coated wood sections of the proposed door frame of FIG. 2A, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0036] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[0037] Embodiments of the present disclosure elaborate upon a lightweight, strong, and durable door frame and door/shutter, which are warpage free, resistant to fire, corrosion, water, and fire, and provide an aesthetic wooden appearance. Further, the embodiments of the present disclosure elaborate upon a method for manufacturing a lightweight, strong, and durable door frame and door/shutter.
[0038] Traditional door frames and doors were made of wood, which was susceptible to warping, cracking, rotting, termites, and fire. As a result, the existing door frames and doors/shutters started employing newer materials such as polyvinyl chloride (PVC), fiberglass, concrete, and aluminum to overcome the termite, wrapping, and rotting issues associated with wooden door frames and doors for improving their longevity. However, these non-wooden materials used in the existing door frames are not strong enough to withstand the load of heavy doors or shutters and may also be difficult to be fixed to the building structures. In addition, these non-wooden materials may still be susceptible to fire, cracking, and deformation under unfavorable conditions, making them unsuitable and prone to failure in the longer run. Moreover, the existing door frames and doors also fail to provide the aesthetic woody appearance and texture provided by traditional wooden frames and doors.
[0039] The present disclosure overcomes the above drawbacks, shortcomings, and limitations associated with existing door frames and doors, by providing and manufacturing a light-weight, strong, and durable door frame and door, which are warpage free, resistant to fire, corrosion, water, and fire, and still provide an aesthetic woody appearance and texture.
[0040] Referring to FIGs. 1 to 2C, method 100 for manufacturing a door frame 200 is disclosed. The method 100 may include step 102 of fabricating or machining a sheet of a first material having a predefined thickness in a predefined shape as shown in FIGs. 2A and 2B to form a first member 202 (also referred to as a support member or reinforcing member 202). The thickness of the first material can be of any thickness. The first member 202 may define the structural shape of the door frame 200. In an exemplary embodiment, the first material may be galvanized steel or a lightweight and strong material that may be resistant to corrosion, fire, termite, and fire, but not limited to the like. However, in other embodiments, the first material may be any stiff material that may be coated with or may comprise additional layers of any or a combination of corrosion-resistant material, fire-resistant, termite-resistant, and fire-resistant materials. Method 100 may further include step 114 of attaching one or more wood sections 204-1 to 204-4 (collectively designated as wood sections or first sections 204, herein) to one or more sides/sections 202-1 to 202-4 of the first member 202 to form the door frame 200. The wood sections 204 may have first predefined dimensions based on a dimension of the sides 202-1 to 202-4 of the first member 202 where the wood sections 2041- to 204-4 are to be fitted.
[0041] In an embodiment, at step 102, the sheet may be bent and/or cut-pressed in different sections 202-1 to 202-5 (also collectively referred to as second sections 202, herein) having second predefined dimensions. Further, the second sections 202-1 to 202-5 formed from the sheet may be welded using the same first material (or any other suitable material) to form the first member 202 having the predefined shape as shown in FIGs. 2A and 2B. However, in some embodiments, a single sheet of the first material (galvanized steel) may be directly bent or machined in the predefined shape to form the first member 202 without requiring any cutting of second sections and welding. Further, the first member 202 may also be manufactured from the first material in the predefined shape using additive manufacturing techniques and all such embodiments are well within the scope of this invention without any limitation.
[0042] In an embodiment, method 100 may further include step 104 of welding one or more flat plates 206, 208 at predefined locations on the first member 202, followed by fitting one or more anchor fasteners (not shown) to the one or more first plates 206, 208. The flat plates 206, 208 may be made of the same first material (galvanized steel) or any other stiff material, to provide additional support and stiffness to the door frame 200. Further, the anchor fasteners may allow the installation or fitting of the door frame 200 to one or more structures.
[0043] In an implementation, the anchor fasteners may be made from materials such as but not limited to steel or brass, and may be designed to provide a secure attachment for the door frame 200. Anchor fasteners may be of various shapes and sizes, selected based on the door frame 200, the door, and the structure where the door frame 200 is to be mounted, to fit different sizes of door frame 200 to the structures. In an exemplary embodiment, the anchor fastener may be a wedge anchor having a wedge-shaped end that may expand as the anchor is tightened, providing a secure grip on the wall or concrete. In addition, the anchor fastener may be a sleeve anchor that may expand as the anchor is tightened, providing a secure hold in concrete or other masonry surfaces. Further, the anchor fastener may be a toggle bolt that may use a spring-loaded toggle mechanism to secure the door frame 200 to drywall or other hollow surfaces. Furthermore, the anchor fastener may be an expansion anchor having a split end that may expand as the anchor is tightened, providing a secure hold in concrete or other masonry surfaces. In other implementations, the anchor fasteners may also be any other anchor fastener known in the art.
[0044] Further, method 100 may include step 106 of welding pre-drilled and tapped pads (not shown) on the first member 202. Predrilled and tapped pads may be metal or alloy components that may be pre-drilled with holes and threaded with screw threads to allow for easy attachment to other parts or surfaces. These pads may have a flat surface with holes drilled at specific intervals. The predrilled and tapped holes on these pads may be used to fasten the door frame 200 to other parts or surfaces such as mounting brackets, support structures, using screws, bolts, or other fasteners. This may allow for easy and precise attachment, as the holes are pre-drilled and threaded to the correct size and pitch, reducing the need for additional machining or drilling.
[0045] In an embodiment, method 100 may include steps 108 of forming at least one cut-out in the member, followed by providing a back cover on the corresponding cut-out. The cut-out may be adapted to accommodate at least a portion of a door lock therein. The door lock may facilitate locking of a door to the door frame 200. Further, the first member 202 configured with the flat plates 206, 208, anchor fasteners, predrilled and tapped pads, and the cut-out, may be clean powder coated using techniques known in the art to protect the first member 202 or door frame 200 from corrosion and damage.
[0046] In an embodiment, at step 110, a piece of wood or plywood may be initially machined to form flat and smooth surfaces which may then be cut into the one or more wood sections 204-1 to 204-4 (first sections) as shown in FIG. 2C, using techniques known in the art. The dimension of the wood sections 204-1 to 204-4 may be selected based on the dimensions of the corresponding sides 202-1 to 202-4 of the first member 202 to where the wood sections 204-1 to 204-4 are to be attached.
[0047] In addition, at step 112, veneer pasting may be done, using a press machine, on the wood sections 204 to create a strong bond between the veneer and the wood sections 204 to coat the veneer on the wood sections 204. In an implementation, at step 110, the wood sections 204 may be polished and glue may be applied on different sides the polished wood section such that at least one of the sides (NV as shown FIG. 2C) remains unglued. Further, at step 112, the veneer may be pasted on the glued wood sections 204 and pressed to coat/paste the veneer on the wood sections 204.
[0048] In an embodiment, step 112 may be repeated multiple times, involving heating and pressing of the veneer-coated wood sections 204 at different temperatures for multiple times to strongly coat the veneer on the wood sections 204 and further enhance the strength of the veneer-coated wood sections 204. Further, at step 114, the unglued side or non-veneer side (NV of FIG. 2C) of the veneer-coated wood sections 204-1 to 204-2 may be attached on the corresponding sides 202-1 to 202-4 of the first member 202 as shown in FIG. 2A to form the door frame 200. For instance, as illustrated, wood section 204-1 may be attached to the side 202-1 of the first member 202, wood section 204-2 may be attached to the side 202-2 of the first member 202, wood section 204-3 may be attached to the side 202-3 of the first member 202, and wood section 204-4 may be attached to the side 202-4 of the first member 202.
[0049] Further, method 100 may include the steps of polishing the formed door frame 200 of step 114 followed by coating the polished door frame 200 with polyurethane for protection of the veneer and also to give a finished clean look to the door frame 200.
[0050] Referring to FIG. 2A to 2C, the present disclosure elaborates upon a door frame 200. The door frame 200 may include a first member 202 having a first predefined shape defining the shape of the door frame 200. The first member 202 may be fabricated from a sheet of galvanized steel or a lightweight and strong material that may be resistant to corrosion, fire, termite, and fire, but not limited to the like. However, in other embodiments, the first material may be any stiff material that may be coated with or may comprise additional layers of any or a combination of corrosion-resistant material, fire-resistant, termite-resistant, and fire-resistant materials. The door frame 200 may further include one or more wood sections (first sections) 204-1 to 204-4 attached to one or more sides 202-1 to 202-4 of the first member 202 to form the door frame 200. As shown in FIG. 2C, the wood sections 204 may have first predefined dimensions based on a dimension of the sides 202-1 to 202-4 of the first member 202 where the wood sections 204-1 to 204-4 are to be fitted.
[0051] The door frame 200 may further include one or more flat plates 206, 208 welded at predefined locations on the first member 202, and one or more anchor fasteners fitted on the flat plates 206, 208. The flat plates 206, 208 may be made of the same first material (galvanized steel) or any other stiff material, to provide additional support and stiffness to the door frame 200. Further, the anchor fasteners may allow the installation or fitting of the door frame 200 to one or more structures.
[0052] Further, the door frame 200 may include one or more predrilled and tapped pads (not shown) provided on the first member 202, where each of the pads may be adapted to receive and engage a hinge screw therewithin. These pads may be used to fasten the door frame 200 to other parts or surfaces such as mounting brackets, and support structures, using screws, bolts, or other fasteners. This may allow for easy and precise attachment, as the holes are pre-drilled and threaded to the correct size and pitch, reducing the need for additional machining or drilling.
[0053] The door frame 200 may further include a cut-out in the first member 202 that may be adapted to accommodate at least a portion of a door lock therein. Further, a back cover may be provided for the corresponding cut-out. In an implementation, the first member 202 being configured with the flat plates 206, 208, anchor fasteners, pre-drilled and tapped pads, and the cut-out, may be clean powder coated using techniques known in the art to protect the first member 202 or door frame 200 from corrosion and damage.
[0054] In an embodiment, the door frame 200 may include a veneer coated on at least one side of the first wood sections 204. Upon coating veneer on the wood sections 204 as explained in detail in the above paragraphs, a non-veneer side (NV of FIG. 2C) of the veneer-coated first wood section may be attached to the sides 202-1 to 202-4 of the first member 202 to form the door frame 200. This may provide the door frame 200 with the aesthetic woody appearance and texture like a traditional wooden door, while the galvanized steel-based first member 202 may keep the door frame 200 lightweight, strong, and durable and further protect the door frame 200 from warpage, fire, corrosion, water, and fire, thereby increasing its longevity.
[0055] In an aspect, (not shown) the present disclosure further elaborates upon a door (also referred to as a shutter) for the door frame 200. The door may be adapted to be movably coupled to the door frame 200 to form a door assembly such that the door may move between a closed position and an open position with respect to the door frame 200. The door may have a dimension based on the overall size of the door frame 200 such that the door may perfectly sit on the door frame 200 in the closed position to cover the door frame 200 opening, and may further keep the opening uncovered in the open position. In an exemplary embodiment, one side of the door may be hingedly coupled to the door frame 200 using predrilled and tapped pads provided on the door frame 200, such that the other side of the door may be free to move and may sit on the door frame 200 in the closed position. In another exemplary embodiment, the door may be a shutter that may be slidably coupled to the door frame 200. In such embodiments, guide rails may extend along the length of the door frame 200 and the door/shutter may be slidably fitted over the guide rails to allow slidable movement of the door between the open position and closed position. However, other sliding or door coupling mechanisms may also be employed to movably couple the door to the door frame 200, and all such embodiments are well within the scope of this invention.
[0056] The door may include a second member having a second predefined shape defining the shape of the door. The second member may be fabricated from a sheet of galvanized steel or a lightweight and strong material that may be resistant to corrosion, fire, termite, and fire, but not limited to the like. The second member of the door may have a cuboidal shape but is not limited to the like. However, in other embodiments, the first material may be any stiff material that may be coated with or may comprise additional layers of any or a combination of corrosion-resistant material, fire-resistant, termite-resistant, and fire-resistant materials. The door may further include one or more sections (third sections) of wood attached to one or more sides of the second member to form the door. The second wood sections 204 may have first predefined dimensions based on a dimension of the sides of the second member where the sections are to be fitted.
[0057] The door may further include one or more flat plates welded at predefined locations on the second member, and one or more anchor fasteners fitted on the first plates. The flat plates may be made of the same first material (galvanized steel) or any other stiff material, to provide additional support and stiffness to the door. Further, the door may include one or more predrilled and tapped pads provided on the second member, where each of the pads may be adapted to receive and engage a hinge screw therewithin. These pads may be used to fasten the door to the door frame 200 using screws, bolts, or other fasteners.
[0058] The door may further include a cut-out in the second member that may be adapted to accommodate at least a portion of the door lock therein. Further, in an implementation, the second member being configured with the flat plates, anchor fasteners, predrilled and tapped pads, and the cut-out, may be clean powder coated using techniques known in the art to protect the second member or door from corrosion and damages.
[0059] In an embodiment, the door may include a veneer coated on at least one side of the second wood section. Once the veneer is coated on the wood sections 204, a non-veneer side of the veneer-coated second wood section may be attached to the sides of the second member to form the door. This may provide the door with the aesthetic woody appearance and texture like a traditional wooden door, while the galvanized steel-based second member may keep the door lightweight, strong, and durable and further protect the door from warpage, fire, corrosion, water, and fire, thereby increasing its longevity.
[0060] Those skilled in the art would appreciate that the novel design of the veneer-coated wood sections pasted on galvanized steel sections (first member and second member) in the door frame and door may provide the door frame and the door with the aesthetic woody appearance and texture like traditional wooden door or door frame. Moreover, the galvanized steel structure may keep the door and door frame lightweight, strong, and durable, which may further protect the door and door frame from warpage, fire, corrosion, water, and fire, thereby increasing their longevity. In addition, the anchor fasteners, the predrilled and tapped pads, the lock cut-out formed in the door frame and door prior to pasting of the veneer-coated wood sections, may allow easier and faster installation of the door frame and door with minimal machining or drilling. This may also reduce wood usage by up to 80% compared to traditional wooden door frames.
[0061] Thus, this invention overcomes the above drawbacks, shortcomings, and limitations associated with existing door frames and doors, by providing and manufacturing a light-weight, strong, and durable door frame and door, which are warpage free, resistant to fire, corrosion, water, and fire, and still provide an aesthetic woody appearance and texture.
[0062] It is to be appreciated by a person skilled in the art that while various embodiments of the present disclosure elaborate upon the implementation of the chassis in electric two-wheeler vehicles, however, the chassis has wider applications where the chassis may be used for non-electric two-wheeler vehicles as well with some modifications, and all such embodiments are well within the scope of the present disclosure, without any limitations.
[0063] Accordingly, the present invention overcomes the above drawbacks, shortcomings, and limitations associated with existing chassis designs and two-wheeler electric vehicles, by designing and developing a simple, improved, and efficient chassis design for two-wheeler vehicles.
[0064] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0065] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0066] Moreover, in interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C ….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[0067] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are comprised to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0068] The proposed invention overcomes the above-mentioned drawbacks, shortcomings, and limitations associated with existing door frames and doors.
[0069] The proposed invention provides a lightweight, strong, and durable door frame and doors for buildings and structures.
[0070] The proposed invention protects door frames and doors from warpage, fire, corrosion, water, and fire and increases their longevity.
[0071] The proposed invention provides a lightweight, strong, and durable door frame and door, that has an aesthetic woody appearance and texture.
[0072] The proposed invention lowers the usage of wood in door frames and doors while still providing strength and the aesthetic woody appearance and texture.
[0073] The proposed invention provides a lightweight, strong, and durable door frame that is warpage free, resistant to fire, corrosion, water, and fire, and provides an aesthetic woody appearance and texture.
[0074] The proposed invention provides a lightweight, strong, and durable door that is warpage free, resistant to fire, corrosion, water, and fire, and also provides an aesthetic woody appearance and texture.
[0075] The proposed invention provides a method for manufacturing a lightweight, strong, and durable door frame that is warpage free, resistant to fire, corrosion, water, and fire, and has an aesthetic woody appearance and texture. , Claims:We Claim:
1. A method (100) for manufacturing a door frame (200), the method (100) comprising the steps of:
fabricating (102) a sheet of a first material in a predefined shape to form a first member (202) defining a shape of the door frame (200); and
attaching (114) one or more first sections (204-1 to 204-2) of wood, having first predefined dimensions based on a dimension of one or more sides (202-1 to 202-4) of the first member (202) and the shape of the door frame (200), to the one or more sides (202-1 to 202-4) of the first member (202) to form the door frame (200).
2. The method (100) as claimed in claim 1, wherein the method (100) of fabricating the sheet into the first member (202) comprises the steps of:
bending and/or cut-pressing the sheet in one or more second sections (202-1 to 202-5) having second predefined dimensions; and
welding the one or more cut-pressed second sections (202-1 to 202-5) using the first material to form the first member (202) having the predefined shape.
3. The method (100) as claimed in claim 1, wherein the method (100) comprises the steps of:
welding (104) one or more flat plates (206, 208) at predefined locations on the first member (202) and fitting one or more anchor fasteners on the one or more flat plates (206, 208); and
welding (106) one or more pre-drilled and tapped pads on the first member (202), wherein each of the pads is adapted to receive and engage a hinge screw therewithin.
4. The method (100) as claimed in claim 1, wherein the method (100) comprises the steps (108) of forming at least one cut-out in the first member (202) and providing a back cover on the corresponding cut-out, wherein the cut-out is adapted to accommodate at least a portion of a door lock therein.
5. The method (100) as claimed in claim 1, wherein the method (100) comprises the steps of:
polishing (110) the one or more wood sections (204-1 to 204-4), and applying glue on one or more sides of each of the polished wood sections (204-1 to 204-4) such that at least one of the sides (NV) remains unglued;
heat-pressing (112) a veneer on the glued sides of the polished wood sections (204-1 to 204-4) to coat the veneer on the glued sides of the wood sections (204-1 to 204-4); and
attaching (114) the unglued side (NV) of the veneer-coated wood sections (204-1 to 204-4) on the one or more sides (202-1 to 202-4) of the first member (202) to form the door frame (200).
6. The method (100) as claimed in claim 5, wherein the method (100) comprises the steps of polishing the formed door frame (200) and coating the polished door frame (200) with polyurethane.
7. The method (100) as claimed in claim 1, wherein the first material is galvanized steel.
8. A door frame (200) and a door assembly comprising:
a door frame (200) adapted to be coupled to a structure, the door frame (200) comprising:
a first member (202) having a first predefined shape defining a shape of the door frame (200), wherein the first member (202) is fabricated from a sheet of galvanized steel; and
one or more first wood sections (204-1 to 204-4), having dimensions based on a dimension of one or more sides (202-1 to 202-4) of the first member (202) and the shape of the door frame (200), attached to the one or more sides (202-1 to 202-4) of the first member (202).
9. The assembly as claimed in claim 8, where the assembly comprises a door adapted to be movably coupled to the door frame (200), the door comprising:
a second member having a second predefined shape defining a shape of the door, wherein the second member is fabricated from a sheet of galvanized steel; and
one or more second wood sections, having dimensions based on a dimension of one or more sides of the second member and the shape of the door, attached to the one or more sides of the second member.
10. The assembly as claimed in claim 8, wherein the door frame (200) comprises:
one or more flat plates (206, 208) welded at predefined locations on the first member (202);
one or more anchor fasteners fitted on the one or more first plates; and
one or more predrilled and tapped pads provided on the first member (202), wherein each of the pads is adapted to receive and engage a hinge screw therewithin.
11. The assembly as claimed in claim 9, wherein each of the door frame (200) and the door comprises at least one cut-out adapted to accommodate at least a portion of a door lock therein.
12. The assembly as claimed in claim 9, wherein the door frame (200) comprises a veneer coated on at least one side of the one or more first wood sections (204-1 to 204-4), wherein a non-veneer side (NV) of the veneer-coated first wood section is attached to the one or more sides (202-1 to 202-4) of the first member (202) to form the door frame (200), and
wherein the door comprises a veneer coated on at least one side of the one or more second wood sections, wherein a non-veneer side of the veneer-coated second wood section is attached to the one or more sides of the member to form the door.