Patent Application
20230160221
The present invention is related to door slab installation tools and, more specifically, to an adaptable door mounting support and methods of use and assembly that allow a user to determine the distance between the bottom edge of an existing door slab mounted to a door frame and the underlying floor, and to preset the distance and to support a replacement door slab at that height above the floor (door gap) to facilitate installation of a replacement door slab to the door frame. Additionally, the adaptable door mounting support allows the top hinge of the existing door to be correspondingly set, so that the replacement door slab will have the top hinge located at the same location as the preexisting door slab.
Existing exterior or interior doors are found everywhere for opening and closing access between two rooms or zones. Occasionally a door slab or doors slabs may need to be replaced and installed in the frame that previously held the door being replaced. Further, replacement of door slabs may be part of a home renovation project.
Currently it is quite difficult to replace a door, and it is a job that one of average do-it yourself (DIY) skills may not have the confidence to tackle. There are essentially two options if a door is to be replaced: one is to use a “pre-hung” door unit (i.e., including of a pre-hinged door slab that is already fastened to a prebuilt door frame), and the other is to replace the door slab using a professional installer while leaving the existing door frame in place. These difficulties may limit the willingness of homeowners to replace their existing doors.
Replacing a door slab with a pre-hung door unit requires the installer to remove the entire existing (or old) door slab and frame from an opening in a wall, and then install a replacement door slab and frame into the opening. This requires a higher level of DIY skill and knowledge. It can take a considerable amount of time and effort if one is not skilled in the procedure. Further, there is no genuine need for a replacement frame, so costs are needlessly increased.
Installing a replacement door slab presents its own unique challenges and is generally more difficult than installing a pre-hung door unit, especially for one with no prior experience. For example, during installation the installer typically needs to lift the replacement door slab into place, which can be awkward and difficult without two people, and then fasten the door slab to the frame. Moreover, the replacement door slab needs to be placed and supported at the same door gap as the existing door slab to facilitate installation of the replacement door slab to the door frame. Further, aid in balancing the replacement door slab and alignment of hinges is needed if the replacement door is to swing as did the original door. Existing supports are cumbersome and require many adjustments.
Therefore, a need exists for an adjustable door support for supporting and holding the replacement door slab at a predetermined distance from a floor to assist with accurately securing a replacement door slab to a door frame.
According to a first aspect of the present invention, there is provided a system for installing a door slab in a door frame. The door gap is defined as the distance between the bottom edge of the door slab pivotally mounted to the door frame through door hinges and the floor. The door mounting support of the invention comprises a frame member including first and second A-shaped segments interconnected by a rectangular bottom section and together defining a door support channel therebetween adapted to receive a portion of the door slab therein, the width of the door support channel being equal to or larger than the thickness of the door slab, and at least one tie device configured to meter the door gap and hold the door slab in place at a height off the ground equal to the door gap. Each of the first and second A-shaped segments is formed with a corresponding first or second top ridge. The at least one tie device includes a cable tie extending between the first and second top ridges and across the door support channel and an adjustable locking member is attached to the cable tie by sliding over the cable tie. The adjustable locking member is slidable over the cable tie in one direction only and lockable on the cable tie to adjust the distance between the cable tie and the bottom section of the frame member.
According to a second aspect of the present invention, there is provided a method for assembling an adaptable door mounting support for acquiring the door gap and for supporting a door slab at a height off the floor equal to the door gap. The door gap is defined as the distance between the bottom edge of the door slab pivotally mounted to a door frame through door hinges and the floor. The method comprises the steps of providing a rectangular sheet. The rectangular sheet includes a plurality of parallel fold lines extending across an entire width of the rectangular sheet, first and second inner rectangular sections each separated from the corresponding one of the first and second outer rectangular sections by one of the fold lines, a rectangular bottom section extending between the first and second inner rectangular sections, the first and second inner rectangular sections interconnected by the rectangular bottom section, wherein each of the first and second inner rectangular sections separated from the rectangular bottom section by one of the fold lines, a first support tab formed on the first outer rectangular section along an outer edge thereof between a first foldable corner tabs and between two first indentations, and a second support tab formed on the second outer rectangular section along an outer edge thereof between a second foldable corner tabs and between two second indentations. Each of the first and second inner sections is formed with a U-shaped cut line adjacent to the bottom section, each of the U-shaped cut lines defining one of corresponding first fixing plate in the first inner section and a second fixing plate in the second inner section each juxtaposed to the bottom section from opposite sides thereof. Each of the first and second inner rectangular sections has at least one elongated tie aperture extending between the first and second inner rectangular sections through the bottom section. The first fixing plate is formed with a first elongated support opening. The second fixing plate is formed with a second elongated support opening. Each of the first and second elongated support openings extends parallel to the fold lines. The method further comprises the steps separating the first and second fixing plates and the first and second inner rectangular sections from the corresponding first and second inner rectangular sections along the cut lines so as to disconnect the first and second fixing plates from the corresponding first and second inner rectangular sections, folding the first and second inner sections relative to the bottom section, folding the first and second outer sections at an acute angle relative to the corresponding one of the first and second inner sections, inserting the first and second support tabs into the first and second support openings to form and secure first and second A-shaped segments each in an upright position relative to the bottom section, each of the first and second A-shaped segments formed with a corresponding first or second top ridge, providing at least one tie device, each of the tie devices including a cable tie and an adjustable locking member slidable over the cable tie, passing the cable tie of the at least one tie device between the first and second top ridges and through the at least one elongated tie aperture, and attaching the locking member of the at least one tie device to a free distal end of the cable tie by sliding over the cable tie.
According to a third aspect of the present invention, there is provided a method of using an adaptable door mounting support for acquiring the door gap and for supporting a door slab at a height off the floor equal to the door gap. The door gap is defined as the distance between the bottom edge of the door slab pivotally mounted to a door frame through door hinges and the floor. The method comprises the steps of providing an adaptable door mounting support including a frame member and at least one tie device configured to meter the door gap and hold the door slab in place at the height off the ground equal to the door gap. The frame member has first and second A-shaped segments interconnected by a rectangular bottom section and together defining a door support channel therebetween adapted to receive a portion of the door slab therein. Each of the first and second A-shaped segments is formed with a corresponding first or second top ridge. The at least one tie device includes a cable tie and an adjustable locking member attachable to the cable tie by sliding over the cable tie and lockable on the cable tie to adjust the distance between the cable tie and the bottom section of the frame member. Next, the cable tie of the at least one tie device is passed through both of the inner rectangular sections of the pre-shaped rectangular sheet and the locking member is attached to free distal end of the cable tie. Then, the door mounting support is positioned under the door slab hung on the door frame so that the first and second A-shaped segments and the rectangular bottom section lay on the floor and a portion of the bottom edge of the door slab is disposed in the door support channel. Then, the door gap is acquired by pulling and raising the cable tie so as to engage the bottom edge of the door slab. Next, the door support is locked into shape by pulling on the cable tie and using the locking member to lock the door support once the cable tie of the door mounting support reaches the height of the door gap.
According to a fourth aspect of the present invention, there is provided a method for installing a replacement door slab in a door frame, the method comprising the steps of providing an adaptable door mounting support including a frame member and at least one tie device, the frame member including first and second A-shaped segments interconnected by a bottom section and together defining a door support channel therebetween adapted to receive a portion of the door slab therein, the at least tie device including a cable tie extending across the door support channel and a locking member attached to the cable tie by sliding the locking member over the cable tie, positioning the door mounting support under the bottom edge of the existing door slab hung on the door frame so that the bottom edge of the existing door slab is disposed in the door support channel of the door mounting support above the cable tie of the at least tie device, acquiring the door gap (defined as a distance between the bottom edge of the existing door slab and the floor) by pulling the cable tie so that a portion of cable tie is raised to touch the bottom edge of the existing door slab, locking the cable tie in place by pushing the locking member toward one of the A-shaped segments, removing the existing door slab from the door frame and from the door mounting support, placing the replacement door slab on the cable tie in the door support channel of the door mounting support, and securing the replacement door slab to the door frame by the door hinges.
Other aspects of the invention, including systems, devices, methods, and the like which constitute parts of the invention, will become more apparent upon reading the following detailed description of the exemplary embodiments.
The accompanying drawings are incorporated in and constitute a part of the specification. The drawings, together with the general description given above and the detailed description of the exemplary embodiments and methods given below, serve to explain the principles of the invention. In such drawings:
Reference will now be made in detail to the exemplary embodiments and exemplary methods as illustrated in the accompanying drawings, in which like reference characters designate like or corresponding parts throughout the drawings. It should be noted, however, that the invention in its broader aspects is not necessarily limited to the specific details, representative materials and methods, and illustrative examples shown and described in connection with the exemplary embodiments and exemplary methods.
This description of exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description, relative terms such as “horizontal,” “vertical,” “front,” “rear,” “upper”, “lower”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “vertically,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion and to the orientation relative to a vehicle body. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship. The term “integral” (or “unitary”) relates to a part made as a single part, or a part made of separate components fixedly (i.e., non-moveably) connected together. Additionally, the word “a” and “an” as used in the claims means “at least one” and the word “two” as used in the claims means “at least two”.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.
The adaptable door mounting support 10 comprises a frame member 12 and one or more (preferably two, as shown in
The frame member 12 is preferably constructed of a foldable material, such as corrugated cardboard. Frame member 12 includes first and second upright A-shaped (or inverted V-shaped) segments 181 and 182, respectively, interconnected by a rectangular bottom section 21, and together forming a door support channel (or slot) 20 therebetween. It will be appreciated that the frame members 12 may be made of other appropriate materials, such as corrugated plastic.
As best shown in
The fold lines 24 allow the outer sections 1911 and 1921 to be folded relative to the inner sections 1912 and 1922, and the inner sections 1912 and 1922 to be folded relative to the bottom section 21 in order form first and second A-shaped segments 181, 182, and to erect the flat sheet 13 into the frame member 12. In this way, the sheet 13 is transformed into the frame member 12 from a flat state, best shown in
The distance between the first and second A-shaped segments 181 and 182 (or between the inner rectangular sections 1912 and 1922) of the frame member 12 in the transverse direction (i.e., the width Wd of the door support channel 20) is equal to or slightly larger than the thickness of the door slab 2. Typical door slabs are usually about 1.5″ to 2.0″ thick. Of course, the fold lines 24 may be placed so as to accommodate door slabs of greater or lesser thickness. The door support channel 20 of the frame member 12 is configured to receive a portion of a conventional door slab therein.
Each of the rectangular inner sections 1912 and 1922 has two elongated tie apertures 26 extending between the inner rectangular sections 1912 and 1922 through the bottom section 21. The elongated tie apertures 26 extend transverse (or orthogonally) to the fold lines 24. Furthermore, each of the inner sections 1912 and 1922 is formed with a U-shaped cut line 28, such as formed by perforations. The U-shaped cut lines 28 are located on the inner sections 1912 and 1922 of the flat sheet 13 adjacent to the bottom section 21. Each of the U-shaped cut lines 28 starts and ends on the corresponding fold line 24. The U-shaped cut lines 28 define a first fixing plate 301 in the first inner section 1912 and a second fixing plate 302 in the second inner section 1922. Both the first fixing plate 301 and the second fixing plate 302 are juxtaposed to the bottom section 21 from opposite sides thereof. As best shown in
The flat sheet 13 further includes first corner tabs 221 foldable relative to the first outer rectangular section 1911 along tab fold lines 25, and second corner tabs 222 foldable relative to the second outer rectangular section 1921 along the tab fold lines 25, as best shown in
The flat sheet 13 also has first and second support tabs 341 and 342, respectively. The first support tab 341 is formed on the first outer rectangular section 1911 of the flat sheet 13 along an outer edge thereof between the first foldable corner tabs 221 and between two first indentations 351. The second support tab 342 is formed on the second outer rectangular section 1922 of the flat sheet 13 along an outer edge thereof between the second foldable corner tabs 222 and between two second indentations 352. The first and second support tabs 341 and 342 are configured to be received in the first and second elongated support openings 321 and 322, respectively.
Each of the tie devices 14 includes a cable tie (or zip tie) 15 and an adjustable locking member (or retaining member) 16, typically a toothed connector, attached to the cable tie 15 by sliding over a free distal end of a strap 15S of the cable tie 15 toward head member 15H provided on a proximal end thereof to lock the cable tie 15 in place. The strap 15S of the cable tie 15 is threaded (i.e., passed through) through one of tie holes 17 formed in the first and second top ridges 241, 242 of the first and second A-shaped segments 181, 182 of the frame member 12 (best shown in
As best shown in in
A method for assembling the door mounting support 10 is as follows.
First, the first and second fixing plates 301 and 302 in the first and second inner rectangular sections 1912 and 1922 of the flat sheet 13 are separated from the corresponding first and second inner rectangular sections 1912 and 1922 along the cut lines 28 by pushing or pulling, so as to disconnect the first and second fixing plates 301 and 302 from the corresponding first and second inner rectangular sections 1912 and 1922.
Then, the flat sheet 13 is folded along the fold lines 24 to form the first and second A-shaped segments 181, 182. To do so, each of the first and second outer sections 1911 and 1921 of the flat sheet 13 is folded at an acute angle relative to the corresponding one of the first and second inner sections 1912 and 1922, and the first and second inner sections 1912 and 1922 are folded perpendicularly (i.e., orthogonally) relative to the bottom section 21 in order form the first and second A-shaped segments 181, 182.
Next, the first support tab 341 is inserted into the first support openings 321 to form and secure the first A-shaped segment 181 in an upright position relative to the bottom section 21, while the second support tab 342 is inserted to the second support opening 322 to form and secure the second A-shaped segment 182 in an upright position relative to the bottom section 21, thus assembling the frame member 12.
Then, the first corner tabs 221 are folded relative to the first outer rectangular section 1911 along the tab fold lines 25 inside the first A-shaped segment 181 and toward the first inner rectangular sections 1912 to be coplanar with the bottom section 21 and to sit flush with the ground/floor 6. Similarly, the second corner tabs 222 are folded relative to the second outer rectangular section 1921 along the tab fold lines 25 inside the second A-shaped segment 182 and toward the second inner rectangular sections 1922 to be coplanar with the bottom section 21 and to sit flush with the ground/floor 6. In this way, the flat sheet 13 of cardboard is transformed from the flat state (shown in
The straps 15S of the cable ties 15 may each be threaded (i.e., passed through) through one of the tie holes 17 formed in the first and second top ridges 241, 242 of the first and second A-shaped segments 181, 182 of the frame member 12 (best shown in
The method of operation (or use) of the door mounting support 10 is as follows.
In use, as best shown in
Then, the straps 15S of the cable ties 15 are each threaded (i.e., passed through) through one of the tie holes 17 formed in the first and second top ridges 241, 242 of the first and second A-shaped segments 181, 182 of the frame member 12 (best shown in
Next, in order to acquire the dimension Sf, the installer positions (by sliding) the door mounting support 10 under the bottom end portion of the existing door slab 2 hung on the door frame 4. In this way, the bottom edge 3 of the door slab 2 is disposed in the door support channel 20 of the door mounting support 10. Next, the free distal ends of the straps 15S are pulled so that a portion of each strap 15S is raised to touch the bottom edge 3 of the door slab 2. Once the straps 15S of the cable ties 15 firmly engage the bottom edge 3 of the door slab 2 (i.e., reach the height of the door gap Sf), the locking members 16 are slid by the installer toward the head member 15H, thus tightening the cable ties 15 and locking the door mounting support 10 into shape and providing strength to the frame member 12 (as best shown in
In this way, the door mounting support 10 acquires (i.e., determines or captures) the door gap Sf (i.e., the distance of the bottom edge 3 of the door slab 2 from the floor 6). The door support 10 is capable of capturing any door gap Sf between about ⅜″ to 1½″, which is sufficient for most installations. As a result, the door mounting support 10 is adjustable to accommodate door assemblies with various door gaps Sf.
During installation of a replacement (or new) door slab, the assembled door mounting support 10 with the captured door gap Sf from the previous door slab is first placed on the floor 6 so as to be ready to support the replacement door slab. Then, the replacement door slab 2 is placed upright onto the door mounting support 10 (as shown in
The door mounting support of the present invention is able to acquire the vertical door gap of the existing door slab and to support the replacement door slab at the same height to facilitate installation of the new/replacement door slab. Because the new/replacement door slab is at the same height as the original door slab, location and mounting to the door hinges also is facilitated. The door mounting support of the present invention allows for quick acquisition of the door gap and achieves the secondary purpose of balancing the new or replacement door for easier installation. The door mounting support of the present invention considerably simplifies door installation procedures, thus allowing a DIY installer to more easily accomplish the task of door replacement.
The foregoing description of the exemplary embodiments of the present invention has been presented for the purpose of illustration in accordance with the provisions of the Patent Statutes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments disclosed hereinabove were chosen in order to best illustrate the principles of the present invention and its practical application to thereby enable those of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated, as long as the principles described herein are followed. Thus, changes can be made in the above-described invention without departing from the intent and scope thereof. It is also intended that the scope of the present invention be defined by the claims appended thereto.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 63/282,975 filed Nov. 24, 2021 by Ege et al., which is hereby incorporated herein by reference in its entirety and to which priority is claimed.
| Number | Date | Country | |
|---|---|---|---|
| 63282975 | Nov 2021 | US |
