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US 2024/0254831 A1Published application
Packaged prehung door system and method
OwnerTodd Bruchu, Craig Johnson +5inventors
InventorsTodd Bruchu, Craig Johnson, Justin Depew, Michael Mordick, Paul Morris, Ben Boenisch, Matt Nelson
Life of this patent
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Abstract
Packaged prehung door systems, components thereof, and related methods are described herein. The packaged prehung door systems described herein may include latch edge retainer apparatus and bottom edge spacer assemblies. Methods of maintaining squareness of the packaged prehung door systems described herein during transportation and installation are also described.
Claims31
A packaged prehung door system comprising:
- a door system frame comprising a hinge side jamb, a latch side jamb, and a sill extending between a sill end of the hinge side jamb and a sill end of the latch side jamb;
- a panel comprising a hinge edge attached to the hinge side jamb and a latch edge facing the latch side jamb, the panel comprising a pair of faces spaced apart from each other and extending from the hinge edge to the latch edge, the panel configured to rotate relative to the hinge side jamb about a hinge axis aligned with the hinge side jamb;
- a lockset bore extending through the panel along a lockset bore axis oriented transverse to the hinge axis;
- a latch bore extending through the panel along a latch axis extending from the lockset bore through the latch edge along a latch axis, wherein the latch axis is transverse to the hinge axis and the lockset bore axis;
- a latch edge retainer apparatus configured to retain the latch edge of the panel in alignment with the latch side jamb, the latch edge retainer apparatus comprising:
- a panel clip comprising an edge plate and a face plate attached to each other along a common edge, wherein the edge plate and the face plate are oriented transverse to each such that when the edge plate is positioned on the latch edge of the panel, the face plate is positioned on a face of the panel and the common edge is proximate a corner formed at a junction between the latch edge and the face of the panel,
- a lock aperture located in the edge plate, the lock aperture defined by a pair of aperture edges, and
- a lock plug comprising a plug body extending along a plug axis, wherein the plug body comprises a bore portion and a latch portion aligned along the plug axis;
- wherein, when the edge plate of the panel clip is located between the latch edge of the panel and the latch side jamb such that the lock aperture is aligned with the latch bore, the face plate is located on a selected face of the panel;
- and wherein, when the bore portion of the lock plug is positioned in the latch bore such that the latch portion protrudes from the latch edge of the panel, the latch portion of the lock plug extends into a latch cavity such that rotation of the panel is prevented by interference between the latch portion of the lock plug and the latch cavity.
7 more elements
A packaged prehung door system comprising:
- a door system frame comprising a hinge side jamb, a latch side jamb, and a sill extending between a sill end of the hinge side jamb and a sill end of the latch side jamb;
- a panel comprising a hinge edge attached to the hinge side jamb and a latch edge facing the latch side jamb, the panel comprising a pair of faces spaced apart from each other and extending from the hinge edge to the latch edge, the panel configured to rotate relative to the hinge side jamb about a hinge axis aligned with the hinge side jamb;
- a deadbolt assembly installed in the panel, the deadbolt assembly comprising a deadbolt configured to extend from and retract into the latch edge of the panel;
- a latch edge retainer apparatus configured to retain the latch edge of the panel in alignment with the latch side jamb, the latch edge retainer apparatus comprising:
- a panel clip comprising an edge plate and a face plate attached to each other along a common edge, wherein the edge plate and the face plate are oriented transverse to each such that when the edge plate is positioned on the latch edge of the panel, the face plate is positioned on a face of the panel and the common edge is proximate a corner formed at a junction between the latch edge and the face of the panel, and
- a lock aperture located in the edge plate;
- wherein, when the edge plate of the panel clip is located between the latch edge of the panel and the latch side jamb, the face plate is located on a selected face of the panel;
- and wherein, when the deadbolt is extended from the latch edge of the panel, the deadbolt extends through the lock aperture into a deadbolt cavity facing the latch edge such that rotation of the panel is prevented by interference between the deadbolt and the deadbolt cavity.
5 more elements
A method of maintaining squareness of a packaged prehung door system, the method comprising:
- installing a latch edge retainer apparatus on and between a latch edge of a panel and a latch side jamb;
- installing a hinge side bottom edge spacer assembly between a bottom edge of the panel and a top of a sill attached to a hinge side jamb to which a hinge edge of the panel is attached;
- and
- installing a latch side bottom edge spacer assembly between the bottom edge of the panel and the top of the sill, wherein the latch side bottom edge spacer assembly is closer to the latch edge of the panel than the hinge side bottom edge spacer assembly.
1 more element
Dependencies are inferred from the claim text.