US 12,065,299 B2
Protective door packaging for prehung door assemblies and method of packaging prehung door assemblies
Steven Farish, Charlotte, NC (US); Tom Abbas, Enola, PA (US); Garrett Burba, Shermans Dale, PA (US); Randy Findley, York Springs, PA (US); Keith Dusharm, Carlisle, PA (US); and Rick Leo, Newport, PA (US)
Assigned to MASONITE CORPORATION, Tampa, FL (US)
Filed by Masonite Corporation, Tampa, FL (US)
Filed on Dec. 8, 2022, as Appl. No. 18/077,408.
Claims priority of provisional application 63/288,183, filed on Dec. 10, 2021.
Prior Publication US 2023/0182986 A1, Jun. 15, 2023
Int. Cl. B65D 81/05 (2006.01); B65B 55/00 (2006.01); B65D 85/64 (2006.01); E06B 7/28 (2006.01)
CPC B65D 81/058 (2013.01) [B65B 55/00 (2013.01); B65D 85/64 (2013.01); E06B 7/28 (2013.01)] 24 Claims
OG exemplary drawing
 
1. A single unit protective door package for packaging of a prehung door assembly, the single unit protective door package comprising:
a single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs;
a pair of upper protective side caps each mounted to the single prehung door assembly at one of opposite upper corners of the door frame;
a pair of lower protective side caps each mounted to the single prehung door assembly at one of lowermost edges of the door frame;
a pair of support spacers each mounted to one of the lowermost edges of the single prehung door assembly for elevating a bottom edge of the door slab above the ground; and
at least a first strap encircling the single prehung door assembly about at least one of the upper protective side caps or the lower protective side caps, wherein each of the support spacers includes a base member having a planar bottom surface adapted to engage a floor surface, and a planar top surface parallel to the planar bottom surface and configured to engage one of the lowermost edges of the door frame, and wherein each of the support spacers further includes a planar connecting member and at least one planar support member extending outwardly from the top surface, and wherein one of the right and left side jambs of the door frame is disposed between the least one planar support member and the connecting member of each of the support spacers.
 
4. A single unit protective door package for packaging of a prehung door assembly, the single unit protective door package comprising:
a single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs;
a pair of upper protective side caps each mounted to the single prehung door assembly at one of opposite upper corners of the door frame;
a pair of lower protective side caps each mounted to the single prehung door assembly at one of lowermost edges of the door frame;
a pair of support spacers each mounted to one of the lowermost edges of the single prehung door assembly for elevating a bottom edge of the door slab above the ground; and
at least a first strap encircling the single prehung door assembly about at least one of the upper protective side caps or the lower protective side caps, wherein each of the upper and lower protective side caps includes a base panel, two side panels and an end panel together forming a U-shaped cavity closed at one end by the end panel, and wherein the right and left side jambs of the door frame are disposed in the U-shaped cavity between the two side panels of each of the upper and lower protective side caps, and
wherein each of the support spacers is disposed between the end panel of one of the pair of lower protective side caps and at least one of the side jambs of the door frame.
 
7. A unitized door packaging of a plurality of single unit protective door packages packaging a single prehung door assembly, the single prehung door assembly comprising a rectangular door frame and a door slab pivotally attached to the door frame, the door frame including right and left side jambs and a header jamb connecting upper ends of the right and left side jambs, the unitized door packaging comprising:
the plurality of the single unit protective door packages stacked and aligned with each other, each of the single unit protective door packages comprising a single prehung door assembly including a pair of upper protective side caps each configured to be mounted to the single prehung door assembly at one of opposite upper corners of the door frame, a pair of lower protective side caps each configured to be mounted to the door assembly at one of lowermost edges of the door frame and a pair of support spacers each mounted to one of the lowermost edges of the door frame for elevating a bottom edge of the door slab above the ground; and
top and bottom tightening straps securing the plurality of stacked single unit protective door packages together by encircling the stacked single unit protective door packages over the upper and lower protective side caps, respectively, of the stacked single unit protective door packages;
the single unit protective door packages are aligned with each other so that bottom surfaces of the support spacers of the single unit protective door packages are aligned, wherein each of the support spacers includes a base member having a bottom surface adapted to engage a floor surface, and a top surface configured to engage one of the lowermost edges of the door frame of an associated single unit protective door package, and
wherein each of the support spacers further includes a connecting member and at least one support member extending outwardly from the top surface and wherein one of the right and left side jambs of each of the door frames is disposed between the least one support member and the connecting member of each of the support spacers.