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, twist, or shift, which compromises the seal between the frame and door panel, and existing shims are not adjustable enough to accurately support and position them within rough openings.
Innovation Solution
An adjustable shim system comprising a base bracket, shim plate, and actuator that can be mounted to a pre-hung door or window frame, allowing for adjustment in both the margin and plumb directions to securely position the door within a rough opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional wooden tapered shim pairs are used to support pre-hung doors, then the door can be positioned within the rough opening, but the shims lack adjustability and precision for accurate alignment
Solution Approach 1:
The shim system transitions from static wooden shims to a dynamic adjustable mechanism. The actuator allows the shim plate to be raised or lowered relative to the base bracket, enabling precise alignment adjustments during installation while maintaining stability once positioned.
Solution Approach 2:
The invention changes the physical parameters of the shim system by introducing an actuator mechanism that allows continuous adjustment of the shim plate position. This enables precise control over the margin and plumb directions, transforming fixed-position shims into adjustable ones with variable parameters.
2Reliability
If pre-hung doors are used to provide a tight fitting seal, then water tightness is improved, but the doors lack rigidity during shipping and installation causing bending and twisting
Solution Approach 1:
The adjustable shim system is pre-installed on the pre-hung door unit during manufacturing, allowing it to provide support and maintain rigidity during shipping and installation. The shims are positioned in advance to prevent bending and twisting before the door is fully installed in the rough opening.
Solution Approach 2:
The shim system acts as an intermediary between the pre-hung door frame and the rough opening structure. It provides the necessary support and rigidity to the door assembly during installation while preserving the integrity of the pre-assembled seal between the frame and door panel.
3Productivity
If multiple wooden shims are used at various locations around the frame, then support is provided, but installation time increases due to manual positioning and lack of adjustability
Solution Approach 1:
The adjustable shim system allows installers to easily adjust the position of shim plates using the actuator mechanism, reducing the need for multiple manual trimming and repositioning operations. The system serves itself by providing built-in adjustability that simplifies the installation process and reduces time consumption.
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 enables easier and more accurate installation of pre-hung doors and windows by providing customizable support, maintaining the seal integrity and ensuring proper alignment, even in varying conditions.
Implementation Method 1
The adjustable shim also includes an actuator operably attached between the base bracket and the shim plate. Rotation of the actuator raises or lowers the shim plate relative to the base bracket.
Data Source
AI summary
An adjustable shim for pre-hung doors or windows is described. The adjustable shim includes a base bracket configured for mounting to a frame member of the pre-hung door or window. The adjustable shim also includes a shim plate and an actuator operably attached between the base bracket and the shim plate. Rotation of the actuator raises or lowers the shim plate relative to the base bracket.