Pre-hung Door Margin Holders for Single-Person Installation
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Solution Overview
Problem
The installation of pre-hung door assemblies typically requires adjustment of margins between the door frame and slab, necessitating two-person operation and increased labor, as the margins must be checked and shimmed to ensure proper sealing during installation.
Innovation Solution
The use of door jamb margin holders, door lock margin holders, and bottom margin holders maintains the desired margins between the door slab and frame, allowing for one-person installation without adjustments, as these holders secure the door in place during shipping, transportation, and installation, and are designed to be fastener-free.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional pre-hung door assembly installation methods are used, then the door can be installed with pre-aligned frame and door, but margin adjustment is required during installation which increases labor requirements and installation complexity
Solution Approach 1:
Margin holders are pre-installed on the door slab during manufacturing to maintain predetermined margins between the door slab and frame. This preliminary action eliminates the need for margin adjustment during installation, allowing a single installer to complete the installation without requiring a second person to check and shim the margins.
2Reliability
If margin adjustment is performed during installation, then proper sealing around the door perimeter is achieved, but two-person operation is required which increases labor time and complexity
Solution Approach 1:
The margin holders are pre-installed during manufacturing to maintain exact predetermined margins, ensuring proper sealing quality is achieved without requiring post-installation adjustment. This eliminates the need for two-person operation while maintaining reliable sealing around the door perimeter.
3Ease of operation
If margin holders are used to maintain predetermined margins, then one-person installation is enabled, but additional components are added to the door assembly
Solution Approach 1:
The margin holders are simple, inexpensive components that are pre-installed on the door slab and then removed after installation is complete. These disposable or temporary components enable one-person installation by maintaining margins during shipping and installation, but are discarded once their function is fulfilled, minimizing their impact on the final door assembly complexity.
4Device complexity
If margin holders are removed after installation, then the door assembly is simplified, but the timing of removal must be coordinated with the installation process
Solution Approach 1:
The margin holders are designed to be pre-installed during manufacturing and then removed as a final step after the door assembly is securely mounted in the rough opening. This timing coordination ensures that the holders maintain margins during critical installation phases but are removed before the installer needs to access the interior of the door, streamlining the overall process.
Data Source
AI summary
The present invention provides a pre-hung door assembly containing a door slab hung inside a door frame. The margins (space between the perimeter of the door and the frame) between the door slab and the door frame are maintained using at least one door jamb margin holder, at least one door lock margin holder, at least one bottom margin holder, or combinations of these holders. The margin holders allow the margins to be maintained and prevent unwanted opening of the door during the shipping and transportation of the door assembly. The jambs of door frame may include predrilled holes for securing the door assembly to the door opening. Details for the door jamb margin holder, the door lock margin holder, and the bottom margin; and methods for installation of the door assembly are also provided.