Door installation system

A door installation system for safely installing or removing a heavy door by a single person. The door installation system generally includes a base, a vertical member extending from the base in an upward manner, a brace member extending between the base and the vertical member, a guide structure attached to the upper portion of the vertical member for guiding an upper portion of a door, and a carriage removably attachable to the base. The carriage is capable of adjusting the attitude of a door being installed to fit within a door jamb. The vertical member and the base are pivotally connected to one another to allow for folding into a compact structure.

CROSS REFERENCE TO RELATED APPLICATIONS

The Applicant has filed U.S. application Ser. No. 11/874,204 on Oct. 18, 2007. No claim of priority is made to U.S. application Ser. No. 11/874,204.

Not applicable to this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to door installers and more specifically it relates to a door installation system for safely installing or removing a heavy door by a single person.

2. Description of the Related Art

Conventional door installers are typically comprised of a structure that receives a door upon a front loading structure. Conventional door installers incline the door rearwardly to prevent the door from falling forwardly. U.S. Pat. No. 7,014,413 to Roland O. Young titled “Door Attaching Apparatus” and U.S. Pat. No. 5,584,635 to Frank Stapelmann titled “Carriage for a Construction Panel” both disclose door installers that have a front loading structure that incline the door rearwardly.

One of the main problems with conventional door installers is that they are not capable of installing or removing heavy doors (e.g. fire doors) which can exceed 200 pounds because of the inherent instability of transporting a heavy door on a front loading structure. Some heavy doors are approximately 400 pounds and can be up to 10 feet in height creating significant tipping forces. When attempting to move a conventional door installer with a heavy door, there is a significant risk that the load will overbalance the door installer resulting in the tipping of the heavy door which can cause physical harm to a person and damage to the heavy door. Another problem with conventional door installers is that they typically require 2 or more workers to utilize because of their inherent stability when working with a heavy door.

Because of the inherent problems with the related art, there is a need for a new and improved door installation system for safely installing or removing a heavy door by a single person.

BRIEF SUMMARY OF THE INVENTION

The general purpose of the present invention is to provide a door installation system that has many of the advantages of the door installers mentioned heretofore. The invention generally relates to a door installer which includes a base, a vertical member extending from the base in an upward manner, a brace member extending between the base and the vertical member, a guide structure attached to the upper portion of the vertical member for guiding an upper portion of a door, and a carriage removably attachable to the base. The carriage is capable of adjusting the attitude of a door being installed to fit within a door jamb. The vertical member and the base are pivotally connected to one another to allow for folding into a compact structure.

There has thus been outlined, rather broadly, some of the features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that will form the subject matter of the claims appended hereto.

An object is to provide a door installation system for safely installing or removing a heavy door by a single person.

Another object is to provide a door installation system that is capable of installing and removing heavy doors exceeding 200 pounds.

An additional object is to provide a door installation system that reduces the chance of injury to a person installing a door.

A further object is to provide a door installation system that reduces the chance of damage to a door being installed or to the surrounding building structures.

Another object is to provide a door installation system that may be operated by a single person.

Another object is to provide a door installation system that allows for adjustment of the attitude of a door along various axes.

Another object is to provide a door installation system that maintains a door centrally positioned in a substantially vertical manner without significant inclination during transport.

Another object is to provide a door installation system that provides a stable base for transporting, installing or removing a heavy door.

Another object is to provide a door installation system that efficiently installs or removes a door.

Another object is to provide a door installation system that easily adjusts to accommodate left swing doors or right swing doors while keeping the door centrally positioned.

Another object is to provide a door installation system that provides a narrow base at the end adjacent the door hinge allowing for easy positioning for door installation.

Another object is to provide a door installation system that allows for easy loading of the door onto the carriage without having to manually lift the door.

Another object is to provide a door installation system that does not require the usage of straps or a secondary apparatus to maintain the position of the door.

Another object is to provide a door installation system that accommodates various widths of doors (e.g. 4 feet, 5 feet).

Another object is to provide a door installation system that may be retracted into a compact storage position.

Another object is to provide a door installation system that provides easy steering when transporting a heavy door.

Another object is to provide a door installation system that prevents unexpected motion when installing or removing a door.

Another object is to provide a door installation system that ensures constant contact with the floor at all time by all wheels thereby increasing stability.

Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention. To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.

DETAILED DESCRIPTION OF THE INVENTION

Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views,FIGS. 1 through 7cillustrate a door installation system10, which comprises a base20, a vertical member40extending from the base20in an upward manner, a brace member50extending between the base20and the vertical member40, a guide structure76attached to the upper portion of the vertical member40for guiding an upper portion of a door, and a carriage60removably attachable to the base20. The carriage60is capable of adjusting the attitude of a door being installed to fit within a door jamb16. The vertical member40and the base20are pivotally connected to one another to allow for folding into a compact structure.

FIGS. 1aand1bbest illustrate the base20. The base20is preferably comprised of an elongated structure having a distal end and an inner end. The base20includes a horizontal member22as best illustrated inFIG. 1aof the drawings. The base20is preferably at least four feet in length to accommodate various widths of doors as the door is positioned substantially parallel with respect to the length of the base20

The upper surface of the base20supports the carriage60during loading, transport and unloading of the door with respect to the present invention. The base20preferably includes a curved upper surface for pivoting the carriage60upon in operation of the present invention as illustrated inFIGS. 1aand1bof the drawings. The base20may be comprised of a tubular structure having a circular cross sectional shape as illustrated in the drawings.

The base20is preferably comprised of a straight structure, however various non-straight structures may be utilized for the base20. The base20is preferably comprised of a narrow structure to allow for positioning a door12near a door jamb16without interference by the base20. In particular, the base20is preferably comprised of a width less than three inches.

The base20may be non-movably attached to the vertical member40forming an L-shaped structure as best illustrated inFIG. 2aof the drawings. However, it is preferable that the base20is movably attached to the vertical member40to allow for folding of the vertical member40with respect to the base20member. In particular, it is preferable that the base20is pivotally attached to the lower end of the vertical member40to allow for folding of the vertical member40upon the base20in a substantially parallel plane forming a compact storage structure as best illustrated inFIG. 2gof the drawings.

The base20is preferably positioned in an offset position with respect to the longitudinal axis of the vertical member40sufficient so that when the carriage60supports the door12that the door12is substantially aligned with the longitudinal axis of the vertical member40as best illustrated inFIG. 5cof the drawings. The central location of the door with respect to the vertical member40increases stability.

The base20is preferably slidably connected to the vertical member40to allow for positioning of the base20into a first offset position or a second offset position with respect to the vertical member40as illustrated inFIGS. 4aand4bof the drawings. The first offset position and the second offset position are each offset with respect to a longitudinal axis of the vertical member40on opposite sides of the vertical member40.

A locking device21is movably attached to the vertical member40and selectively engages the base20to maintain the base20in either the first offset position or the second offset position as further shown inFIGS. 1aand1bof the drawings. The locking device21preferably pivots about a guide rod28that is attached to a vertical portion25of the base20. The guide rod28slidably extends through two brackets extending from the cross member24as shown inFIG. 1aof the drawings.

The vertical portion25extends upwardly from the inner end of the base20to allow for pivotal attachment of the base20with respect to the vertical member40in a distally spaced manner when they are folded together. The locking device21includes a tooth23that extends inwardly toward and to the side of the vertical portion25of the base20thereby preventing side-to-side movement of the base20. When the locking device21is pivoted upwardly, the tooth23is removed from the side of the vertical portion25thereby allowing the base20to slide between the first offset position and the second offset position with respect to the vertical member40.

At the distal end of the base20, a latch36is attached in a biased manner to secure the base20to the vertical member40. The latch36selectively catches upon the guide structure76when the base20is folded with respect to the vertical member40as best illustrated inFIGS. 2fand2gof the drawings. The latch36prevents removal of the vertical member40and the base20from one another unless a user manipulates the latch36to release the same.

C. Vertical Member

The vertical member40extends upwardly from the inner end of the base20as shown inFIGS. 1aand2aof the drawings. The vertical member40is comprised of an elongated structure that preferably extends vertically upward when the present invention is in the expanded position. The vertical member40preferably has a length of at least four feet to accommodate doors of significant heights such as ten feet.

A cross member24is preferably attached to a lower end of the vertical member40as shown inFIG. 1aof the drawings. The cross member24provides side-to-side support to the present invention during operation thereof. The cross member24is preferably at least three feet in length and the vertical member40preferably is attached centrally within the cross member24to ensure adequate stability regardless of what position the base20is in with respect to the vertical member40.

FIGS. 1a,1b,1eand1fillustrate the carriage60which is supported by the base20. The carriage60is preferably removably supported upon the base20to allow the present invention to fold into a compact storage position. When the carriage60is removed from the base20, the carriage60is attached to the side of the vertical member40as illustrated inFIG. 2bof the drawings.

The carriage60is comprised of a lower receiver62that receives the base20as illustrated inFIGS. 1eand1fof the drawings. The lower receiver62preferably forms a channel that slidably receives the upper part of the base20as best illustrated inFIG. 1of the drawings. The channel may be comprised of various cross sectional shapes that allow for pivoting about the surface of the base20. The pivoting of the carriage60upon the base20allows for adjustment of the pitch angle of the door12.

The lower receiver62is further preferably slidably positionable upon the base20to allow for adjustment of the carriage60to a central location of the door12for doors12of various widths. The sliding of the lower receiver62ensures that the door12is properly positioned with respect to the guide structure76.

The lower receiver62includes guide portions64that extend inwardly to slidably receive the lifting member70. A support bar extends between the opposing sides of the lower receiver62to provide support and to connect the actuator68to.

The lifting member70is comprised of a broad structure and includes a lip member72extending outwardly to engage the bottom edge14of the door12as best illustrated inFIG. 1fof the drawings. The lip member72preferably includes a gripping material74to prevent movement of the door12when positioned upon the lip member72. The lip member72preferably extends along the entire length of the lifting member70to provide increased support to the door12. A pair of ear members71are attached to the rear surface of the lifting member70and extend along the backside of the guide portions64to form a sliding slot to guide the lifting member70along the guide portions64. The lifting member70moves upwardly and downwardly base20dupon the lifting force applied by the actuator68.

A pair of support arms66extend from the lower receiver62and extend upwardly as shown inFIGS. 1aand1eof the drawings. The support arms66are attached to an upper member67forming a triangular shape.

A cam63is pivotally attached to the upper member67and a roll lever61is attached to the cam63to manipulate the cam63. The cam63is comprised of an uneven shaped structure that moves the connecting member69when rotated.

The connecting member69is attached in a vertical manner to the lifting member70and to the actuator68as shown inFIG. 1eof the drawings. The upper portion of the connecting member69preferably includes a channel that receives the cam63so that when the cam63is rotated the connecting member69is moved from left to right or vice-versa to allow for adjustment of the roll angle of the door as shown inFIGS. 6athrough6cof the drawings. As the cam63is rotated within the connecting member69, the connecting member69and the lifting member70have their roll angle adjusted accordingly and slide/adjust within the lower receiver62as shown in the figures.

The actuator68may be comprised of a hand operated device or powered device to cause the lifting/lowering of the lifting member70. The actuator68is attached at its upper end to the connecting member69and the lower end to the support bar of the lower receiver62. The actuator68allows for adjustment of the door height in use.

FIG. 2aillustrates the carriage60removably attached to the vertical member40in a storage position. A lower support54extends outwardly from the vertical member40and has an extended portion that extends upwardly. An aperture within the lip member72is positioned around the extended portion with the upper end of the connecting member69received within a jaw57of a sliding upper support56wherein an upper locking member58is biased and extends into an opening within the vertical member for selectively locking the upper support56in a lowered or raised position.FIG. 2aillustrates the upper support56in a lowered position thereby retaining the carriage60in the storage position.FIG. 2cillustrates the upper support56in the raised position thereby allowing the carriage60to be removed from the vertical member40.

E. Guide Structure

The guide structure76attached to an upper portion of the vertical member40as best illustrated inFIGS. 1aand1cof the drawings. The guide structure76is designed for guiding an upper portion of the door positioned upon the carriage60as illustrated inFIGS. 6athrough6eof the drawings.

The guide structure76is preferably movable from left to right thereby manipulating a pitch angle of the door. The guide structure76is preferably comprised of a first guide member42and a second guide member44forming a receiver slot between thereof. The first guide member42and the second guide member44are preferably comprised of a rigid member surrounded by a padding material to protect the door. (e.g. foam rubber).

The first guide member42and the second guide member44extend substantially parallel with respect to one another and with respect to the base20. The first guide member42and the second guide member44are preferably pivotally attached to the vertical member40to allow for positioning of the door12between the guide members. As shown inFIG. 5cof the drawings, the door12is positioned against one of the guide members first when the other guide member is pivoted upwardly and then the remaining guide member is lowered to secure the door12between the guide members in a secure position and with limited movement as shown inFIG. 5dof the drawings.

As shown inFIG. 1cof the drawings, an arm member41is pivotally attached to the vertical member40and supports the guide members upon a horizontal post. The guide members pivot about the horizontal post. A locking lever47is pivotally attached to the arm member41in a biased manner by the biasing member46and allows for locking of the guide member in the horizontal position as shown inFIG. 1cof the drawings. A lower lip extends from the inner portion of the locking lever47that is positioned below a first locking member43on the first guide member42and a second locking member45on the second guide member44to prevent rotation of the guide members upwardly when the locking lever47is in a normal state but allows rotation of the guide members when released.

A handle48is rotatably attached to the vertical member40along with a friction member49to reduce movement of the handle48. The handle48has an extended portion that extends upwardly into an open lower end of the arm member41thereby causing rotation of the arm member41when the handle48is rotated.

F. Brace Member

A brace member50having a first end and a second end is preferably attached between the base20and the vertical member40. The first end is preferably pivotally connected to the base20and the second end is connected to the vertical member40in either a pivotal manner or removable manner. The second end of the brace member50is preferably attached to a bracket extending from the vertical member by an attachment device52(e.g. using a pin from the second end extending through an opening in the bracket along with a sliding collar that prevents the pin from being removed).

It is preferably that the second end of the brace member50is pivotally attached to the vertical member40to allow for folding of the vertical member40with respect to the base20without having to remove the brace as illustrated inFIGS. 7athrough7c. A sliding member51is preferably slidably positioned about the vertical member40and a pin member53extends substantially horizontally from the sliding member51as shown inFIG. 7cof the drawings. The second end of the brace member50is pivotally and slidably attached to the pin member53thereby allowing adjustment of the base20with respect to the vertical member40for storage and for the two offset positions.

A securing member59extends through the sliding member51in a biased manner and selectively engages a locking aperture within the vertical member40to secure the vertical member40substantially 90 degrees with respect to the base20as shown inFIGS. 7athrough7cof the drawings.

G. Support Wheels

FIG. 1abest illustrate a pair of support wheels26attached to the cross member24. The support wheels26are preferably comprised of caster wheels with brakes incorporated within to allow for braking of the present invention. The caster wheels allow for free movement of the present invention near the vertical member40.

H. End Wheel

FIG. 1afurther illustrates an end wheel30attached to said distal end of said base20to provide for longitudinal movement of the present invention when engaging the ground surface. The end wheel30is designed for supporting the load of the door12and preferably is rotatable only about a horizontal axis that is substantially perpendicular to the base20to provide easy transportation of the door. The ability to rotate only about the horizontal axis, preferably parallel to the base20, prevents the door12from unexpected moving when installing the door12.

I. Secondary Wheel

A foot lever34is movably attached to the base20and a secondary wheel32is connected to the foot lever34as shown inFIGS. 1aand1bof the drawings. The secondary wheel32is substantially transverse with respect to the end wheel30and elevates the base20member and the end wheel30when the foot lever34is depressed.

The secondary wheel32is mechanically connected to the foot lever34by a pair of lever members that are substantially parallel to one another attached to a vertical axle supporting the secondary wheel32. The foot lever34is biased by a spring or other biasing member to maintain the secondary wheel32in an elevated state unless the foot lever34is depressed.

The secondary wheel32rotates about a rotational axis that is substantially parallel with respect to a longitudinal axis of the base20as shown inFIG. 1aof the drawings. The secondary wheel32allows for moving of the door12closer to the door jam during installation by rotating the distal end of the base20with respect to the vertical member40.