Adjustable Shim for Pre-Hung Door Alignment
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Solution Overview
Problem
Pre-hung doors lack rigidity during installation, causing them to bend, bow, or shift, which affects the quality of the seal between the frame and door panel, and require skilled installation to properly position within a rough opening.
Innovation Solution
An adjustable shim system comprising a base bracket, inner and outer shims, and an actuator that allows linear translation of the inner shim relative to the outer shim, enabling precise adjustment of the shim's height to support and position the pre-hung door accurately within the rough opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tapered shim pairs are used to support and position the pre-hung door, then the door can be installed within the rough opening, but the installation process remains highly dependent on installer skill and the door may still shift or misalign during handling
Solution Approach 1:
The shim system incorporates an adjustable mechanism with a screw thread that allows the shim thickness to be dynamically changed during installation. This enables the installer to adjust the shim height to compensate for variations in the rough opening and door frame, achieving accurate alignment without requiring advanced installation skills. The dynamic adjustment capability directly addresses the contradiction by making the system both reliable and easy to operate.
2Reliability
If pre-hung doors are pre-assembled to provide a tight fitting seal, then the seal quality between frame and door panel is improved, but the door lacks rigidity and may bend, bow, or twist during shipping and handling
Solution Approach 1:
The adjustable shim system is pre-configured with an adjustment mechanism that allows for fine-tuning during installation. By preparing the shim with adjustment capabilities beforehand, the system can compensate for any deformation that occurs during shipping and handling, ensuring that the door maintains proper alignment and seal quality without requiring the door itself to be more rigid.
3Adaptability or versatility
If the shim height is fixed, then the manufacturing process is simpler, but the shim cannot accommodate variations in rough opening dimensions or door frame positioning requirements
Solution Approach 1:
The shim incorporates a screw thread mechanism that allows the height to be dynamically adjusted. This dynamic feature enables the shim to adapt to various rough opening dimensions and door frame positioning requirements while maintaining a relatively simple overall structure. The adjustment mechanism adds minimal complexity but provides significant adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adjustable shim system simplifies and enhances the installation of pre-hung doors by allowing easy adjustment to take up space between the door frame and studs, improving the door's alignment and seal quality, reducing dependence on installer skill, and facilitating accurate positioning within the rough opening.
Implementation Method 1
Rotation of the first actuator translates the inner shim substantially linearly relative to the outer shim, thereby adjusting a combined height of the inner shim and the outer shim
Data Source
AI summary
An adjustable shim is described for attachment to a pre-hung door or a rough opening. The adjustable shim may include a base bracket for mounting the adjustable shim to the pre-hung door or the rough opening, an inner shim, an outer shim, and a first actuator operably attached between the base bracket and the inner shim. At least one of the inner shim and the outer shim is tapered. Rotation of the first actuator translates the inner shim substantially linearly relative to the outer shim, thereby adjusting a combined height of the inner shim and the outer shim.