Pre-hung Door Installation Tool with Level and Spacer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The installation of pre-hung doors typically requires two people, is labor-intensive, and can result in misalignment and reduced rigidity due to bending or shifting during shipping and handling, affecting the seal between the door frame and panel.
Innovation Solution
A tool with a base, orientation indicators (such as bubble levels), spacers, and a tongue design that maintains alignment and rigidity by positioning between the door panel and frame, allowing single-person installation and ensuring proper alignment during shipping, handling, and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-hung door is pre-assembled to provide tight fitting seal, then seal quality is improved, but installation requires two people and becomes labor intensive
Solution Approach 1:
The patent applies preliminary action by pre-assembling the door unit with the frame and panel before installation, and by including installation tools (level, spacers, clamps) pre-attached to the door unit. This allows the door to maintain its pre-assembled seal quality while enabling faster single-person installation through pre-prepared alignment and fastening components.
2Ease of operation
If pre-hung door lacks rigidity prior to installation, then shipping and handling becomes easier, but door portions bend, bow, twist or shift reducing seal quality
Solution Approach 1:
The patent applies preliminary action by pre-attaching installation tools including spacers and clamps to the door unit before shipping. These pre-attached tools maintain proper alignment and rigidity during shipping and handling, preventing bending, bowing, or twisting that would compromise seal quality, while still allowing easy installation when the tools are removed and used.
3Device complexity
If installation tools are not pre-attached, then door unit is simpler, but alignment and spacing depend on installer skill
Solution Approach 1:
The patent applies merging by combining the installation tools (level, spacers, clamps) with the door unit itself through pre-attachment. This integration ensures that alignment and spacing tools are always present and properly positioned, eliminating dependence on installer skill while maintaining reasonable door unit simplicity through standardized tool designs.
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 tool simplifies and speeds up the installation process, reduces labor costs, and maintains the pre-assembled seal quality by ensuring proper alignment and rigidity of the pre-hung door.
Implementation Method 1
The tool includes a base and at least one orientation indicator, such as a bubble level, mounted to the base
Data Source
AI summary
A tool for use during installation of a pre-hung door. The tool includes a base and at least one orientation indicator, such as a bubble level, mounted to the base. The tool also includes at least one spacer extending from the base. The at least one spacer may be positioned between an edge of a door panel and a respective adjacent portion of a door frame. The tool may also include at least one tongue extending from the base in a direction opposite the at least one spacer. The at least one tongue may be positioned between a weather strip and a face of the door frame so that the tool can remain in place when the door panel is open relative to the door frame.