Adaptable Door Mounting Support for Replacement Slab Installation
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Solution Overview
Problem
Existing methods for replacing doors are complex and require high DIY skills, involving cumbersome supports and precise measurements, making it difficult for average individuals to install a replacement door slab without professional assistance.
Innovation Solution
A system comprising an adaptable door mounting support with a frame member and tie devices, including cable ties and locking tabs, allows for easy measurement and support of the door gap, enabling the removal of the existing door slab and secure installation of a new one with minimal tools and expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional door replacement methods are used, then the door can be installed with proper alignment, but the process requires high DIY skills, multiple tools, and considerable time
Solution Approach 1:
The door replacement system is divided into separate functional components: a door support device for holding the door at proper height, a hinge positioning device for accurate hinge location, and a frame removal device for eliminating the old door frame. Each component performs a specific function, allowing the installer to complete the replacement without needing master carpentry skills or a full toolkit.
Solution Approach 2:
The door support device automatically maintains the door at the correct height relative to the floor, eliminating the need for continuous manual adjustment. The hinge positioning device self-adjusts to locate hinge centers accurately, and the frame removal device automatically positions itself to remove the old frame, reducing the skill level required for proper installation.
2Ease of operation
If pre-hung door units are used, then installation is simpler, but the entire door frame must be removed and reinstalled
Solution Approach 1:
The invention extracts only the door slab from the existing door frame, allowing the frame to remain in place. The frame removal device selectively removes the old door frame components (jamb, head, sill) while leaving the rough opening intact, enabling replacement of just the door slab rather than the entire pre-hung unit.
Solution Approach 2:
The door support device serves multiple functions: it holds the door at proper height during installation, positions the door for hinge attachment, and supports the door while the new frame is installed. This multi-functionality eliminates the need for multiple specialized tools that would be required for traditional door replacement.
3Manufacturing precision
If accurate hinge positioning is performed manually, then proper door alignment is achieved, but repeated measurements and adjustments are required
Solution Approach 1:
The hinge positioning device replaces manual measurement and marking with a mechanical system that automatically locates hinge centers. The device uses geometric relationships and physical constraints to position hinges accurately without requiring the installer to take measurements or make repeated adjustments, saving considerable time while maintaining precision.
4Ease of operation
If traditional door support methods are used, then the door can be held in place, but cumbersome supports requiring many adjustments are needed
Solution Approach 1:
The door support device is designed to self-adjust to the correct door height by using the floor as a reference surface. Once positioned, it automatically maintains the door at the proper elevation without requiring the installer to make continuous adjustments or use multiple shims and blocks, simplifying the support process significantly.
Data Source
AI summary
A system for installing a door slab in a door frame. The system comprises an adaptable door mounting support configured to acquire a door gap and to support the door slab at a height off of the ground equal to the door gap. The door mounting support includes a frame member and at least one tie device provided to meter the door gap and hold the door slab in place off the ground at the height equal to the door gap. The frame member includes two A-shaped segments interconnected by a bottom section and together defining a door support channel therebetween. The at least tie device includes a cable tie extending across the door support channel and a locking tab attached to the cable tie by sliding the locking tab over the cable tie. The locking tab is lockable on the cable tie.