Door Stabilization Device for Pre-Hung Door Installation
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Solution Overview
Problem
Installing pre-hung doors can be challenging due to difficulties in maintaining level and proper spacing, and existing tools do not effectively address the stabilization and shipping issues.
Innovation Solution
A door stabilization device comprising a clip component and fastener components that attach to the door and door frame using compression fits, preventing pivoting and ensuring correct spacing through a system of parts that attach to multiple edges of the door, including a top part, hinge side part, and strike side part, with optional level devices for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual installation methods are used for pre-hung doors, then the installation process is simple in terms of tools, but the installation precision and stability are poor due to difficulty in maintaining level and proper spacing
Solution Approach 1:
The stabilization device is divided into multiple independent components: a clip component with first and second sides, a fastener component with shaft and head portions, and optional level devices. Each component performs a specific function - the clip provides compression fit attachment, the fastener provides secure coupling, and the level devices provide alignment guidance. This segmentation allows for precise installation while keeping each individual component relatively simple.
Solution Approach 2:
The stabilization device acts as an intermediary tool between the installer and the door assembly. It temporarily couples the door to the door frame during installation, providing the necessary stability and alignment guidance. The device includes removable stabilization members that interface with both the door and door frame, mediating the installation process and ensuring proper positioning before permanent installation.
2Stability of the object's composition
If pre-hung doors are prepared for shipping without stabilization devices, then the shipping process is simpler, but the doors are prone to movement and damage during transport
Solution Approach 1:
The stabilization device is installed on the door assembly before shipping to prevent movement during transport. The clip component is attached to the door edge and the fastener component extends through the door into the door frame, securing the door in place. This preliminary stabilization action ensures the door maintains its position during shipping, and the device can be removed after installation is complete.
3Strength
If multiple fasteners are used to secure the door to the door frame, then the door is more securely attached, but the installation process becomes more time-consuming
Solution Approach 1:
The stabilization device combines multiple fastening functions into a single integrated assembly. The clip component and fastener component work together as one unit to secure the door to the door frame. The first and second sides of the clip component engage with the door edge simultaneously, and the fastener component provides both attachment and alignment functions. This merging reduces the number of separate installation steps while maintaining strong attachment.
Solution Approach 2:
The stabilization device is designed to be self-aligning and self-securing to some extent. The level devices integrated into the clip component automatically indicate when proper alignment is achieved, eliminating the need for separate alignment measurements. The compression fit design of the clip component allows it to self-adjust to the door edge dimensions, reducing the need for precise manual adjustments during installation.
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 solution provides accurate and stable installation and shipping of pre-hung doors by maintaining correct spacing and preventing door movement during transport and installation, ensuring proper alignment and operation.
Implementation Method 1
The clip component is configured to fit onto an edge of a door using a compression fit between the first side portion and the second side portion
Implementation Method 2
The first side compressible portion engages a face of the door and applies a pressure to the face of the door when the clip component is installed on the edge of a door
Data Source
AI summary
Embodiments include a door stabilization device. The door stabilization device can include a clip component, a first fastener portion, and a second fastener portion. The clip component can be configured to fit onto an edge of a door using a compression fit between the first side portion and the second side portion. The first fastener portion is configured to extend through a clip aperture defined by the clip component and at least partially into a latchbolt aperture defined by the door. The second fastener portion configured to mate with the first fastener portion and configured to fit at least partially within the latchbolt aperture and a door knob bore defined by the door. Other embodiments are also included herein.