A door assembly. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a pair of side jambs. The invention may also be considered a frame member. The frame member may include a core; and a two-piece top piece adjoining the core to form a structural member. The core and the top piece may be a composite of cellulosic material and at least one other material. The door assembly may further include at least one adjacent panel. Also disclosed are door jamb frame members and mullion frame members.
1. A door assembly, said door assembly comprising:
(a) at least one door panel; and
(b) a door frame having a plurality of frame members including a header and at least a pair of side jambs; wherein at least one frame member includes
(i) a core; and
(ii) at least one top piece adjoining said core to than a structural member with said core and wherein said top piece is a composite of cellulosic material and plastic,
wherein the amount of cellulosic material in said cellulosic-plastic composite is between 20 wt. % and 70 wt. % of the weight of said cellulosic-plastic composite when a thickness of the top piece is between 10% and 50% of the thickness of the at least one frame member.
2. In a door assembly including a door frame having a plurality of frame members including a header and at least a pair of side jambs, at least one frame member comprising:
(a) a core; and
(b) a two-piece top piece adjoining said core to form a structural member with said core and said top piece is a composite of cellulosic material and plastic,
wherein the amount of cellulosic material in said cellulosic-plastic composite is at least 20 wt. % of the weight of said cellulosic-plastic composite when a thickness of the top piece is at least 10% of the thickness of the at least one frame member.
3. The frame member according to claim 2 , wherein said core is formed of a non-metallic material.
4. The frame member according to claim 3 , wherein said core is wood.
5. The frame member according to claim 4 , wherein the core further includes a lower portion formed of a decay resistant material.
6. The frame member according to claim 5 , wherein said lower portion formed of a decay resistant material is a cellulosic-plastic composite.
7. The frame member according to claim 6 , wherein said cellulosic portion of said cellulosic-plastic composite is wood fiber.
8. The frame member according to claim 6 , wherein said plastic portion of said cellulosic-plastic composite is a thermoplastic.
9. The frame member according to claim 2 , wherein said two-piece top piece includes a stop portion and a rabbet portion.
10. The frame member according to claim 9 , wherein said stop portion and said rabbet portion are generally L-shaped and the proximate end of said stop portion overlaps the corresponding proximate end of said rabbet portion.
11. The frame member according to claim 10 , wherein the overlapping proximate ends of said rabbet portion and said stop portion form a weather strip slot.
12. The frame member according to claim 9 , wherein said stop portion and said rabbet portion are generally L-shaped and the distal ends of said stop portion and said rabbet portion each overlap the sides of the underlying core.
13. The frame member according to claim 2 , wherein said two-piece top piece is formed of a decay resistant material.
14. The frame member according to claim 13 , wherein said two-piece top piece is a cellulosic-plastic composite.
15. The frame member according to claim 13 , wherein the amount of cellulosic material in said cellulosic-plastic composite is between 20 wt. % and 70 wt. % of the weight of said cellulosic-plastic composite.
16. The frame member according to claim 15 , wherein the amount of cellulosic material in said cellulosic-plastic composite is between 25 wt. % and 45 wt. % of the weight of said cellulosic-plastic composite.
17. The frame member according to claim 16 , wherein the amount of cellulosic material in said cellulosic-plastic composite is 35 wt. %+/−5% of the weight of said cellulosic-plastic composite.
18. The frame member according to claim 2 , wherein the thickness of the two-piece top piece is between 10% and 50% of the thickness of said frame member.
19. The frame member according to claim 18 , wherein the thickness of the two-piece top piece is between 20% and 40% of the thickness of said frame member.
20. The frame member according to claim 2 , wherein the thickness of the two-piece top piece is at least 30% of the thickness of said frame member.
21. The frame member according to claim 2 , further including a binder between said core and said two-piece top piece for attaching said core to said two-piece top piece to form said frame member.
22. A door assembly, said door assembly comprising:
(a) at least one door panel; and
(b) a door frame having a plurality of frame members including a header and a side jamb; wherein at least one frame member includes
(i) a core; and
(ii) a two-piece top piece adjoining said core to form a structural member with said core and said top piece is a composite of cellulosic material and plastic, wherein the amount of cellulosic material in said cellulosic-plastic composite is between 20 wt. % and 70 wt. % of the weight of said cellulosic-plastic composite when a thickness of the top piece is between 10% and 50% of the thickness of the at least one frame member; and
(c) at least one adjacent panel.
23. The door assembly according to claim 22 , wherein said plurality of frame members includes a mullion.