INSERTABLE FRAME

TECHNICAL FIELD

The disclosure herein relates to apparatus and methods for assembling an insertable frame within a receiving frame.

BACKGROUND

In construction of buildings that include pre-hung doors or windows for installation into walls or doorways, a contractor provides typically constructs rough openings according to the building construction specifications. Frames are then inserted therein manually. Prerequisite to a properly installed window or door, the window or door frames must be accurately aligned within their respective receiving support frames and fixedly secured. For accurate alignment during construction, the receiving window or door jambs must be level, and the inserted window or door frames must be square. The assembled window or door frames are usually acquired from commercial suppliers based on pre-specified dimensions for placement within the receiving frame.

During installation, the door or window frame is retained level or plumb, and rendered in fixed position stationary prior to use of spacers or wedges placed to support the prefabricated door or window frame within the receiving support structure. The shims adjust the window edges or door jamb to level positions. By manually positioning combinations of wedges, the insertable frame can be positioned and fixedly retained. Mounting of the insertable frame typically requires considerable time for installation, given the task of locating and properly positioning the shims to ensure a level window or door frame, and is often prone to manual error and unnecessary repetitions of the manual effort. Failure to ensure an accurate installation has consequences for reduced life of the installed assembly by way of fluid leaks and penetration, and a less thermally efficient door or window, causing increased maintenance and expenses.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates, in an example embodiment, system 100 that uses an adjustable shim to align and secure an insertable frame within a receiving frame.

FIG. 2 illustrates, in example embodiment configuration 200, an adjustable shim for aligning and securing an insertable frame within a receiving frame.

FIG. 3 illustrates, in an example embodiment, method 300 of aligning and securing an insertable frame within a receiving frame using more than one adjustable shims.

FIG. 4 illustrates, in example embodiment configuration 200, an adjustable shim for aligning and securing an insertable frame within a receiving frame.

DETAILED DESCRIPTION

The disclosure herein pertains to a novel adjustable shim usable for easily and accurately aligning and securing an insertable frame, such as a window frame, a pre-hung door frame, or a panel frame, within a receiving frame. The configuration of the adjustable shim further allows for ingress and overflow of a fluid sealant material, such as a sealant foam that may be applied under pressure to the gap between the insertable frame and the receiving frame, in a manner that advantageously results in significantly enhanced sealing against fluid leaks and thermal losses.

Provided is an apparatus for aligning and securing an insertable frame within a receiving frame. The apparatus includes an adjustable shim comprising a securing plate having a support surface and a threadably configured inner portion, the support surface adapted to support an edge of the insertable frame; and a base portion arranged in threadable coupling with the threadably configured inner portion of the securing plate, the base portion adapted for fixed arrangement onto an edge of the receiving frame; wherein a rotation of the securing plate in accordance with the threadable coupling translates the support surface of the securing plate towards the edge of the insertable frame and away from the edge of the receiving frame.

Also provided is a method of aligning and securing an insertable frame within a receiving frame. The method comprises positioning a first adjustable shim intermediate the insertable frame and the receiving frame, the first adjustable shim being fixedly positioned at a first position along an edge of the receiving frame; positioning at least a second adjustable shim intermediate the insertable frame and the receiving frame, the at least a second adjustable shim being fixedly positioned at an at least a second position along the edge of the receiving frame; and upon verifying a level alignment of the insertable frame within the receiving frame, securing the insertable frame in the level position by adjusting the first and at least a second adjustable shims; wherein each of the first and the at least a second adjustable shims comprise: a securing plate having a support surface and a threadably configured inner portion, the support surface adapted to support the edge of the insertable frame, and a base portion arranged in threadable coupling with the threadably configured inner portion of the securing plate, the base portion adapted for fixed arrangement onto the edge of the receiving frame; and wherein the securing is accomplished in accordance with a rotation of the securing plate that translates the support surface of the securing plate towards the edge of the insertable frame and away from the edge of the receiving frame.

FIG. 1 illustrates, in an example embodiment 100, a system that uses an adjustable shim to align and secure an insertable frame within a receiving frame. Adjustable shim 101 in one embodiment may be interposed, in stages or steps as will be discussed in regard to FIG. 3 below, between insertable frame 102 and receiving frame 103. Insertable frame 102 may be such as a window frame or assembly, a pre-hung door, or a panel frame. Receiving frame 103 being of fixed construction, such as a doorway frame or a window receiving frame. FIG. 1 shows, in the embodiment depicted, adjustable shim 101 disposed at multiple locations, on several edges along insertable frame 102. Along any particular edge of insertable frame 102, and of receiving frame 103, each one of a pair of adjustable shims 101 may be placed in distal locations relative to the other of the pair, in an embodiment.

FIG. 2 illustrates, in a detailed example embodiment configuration 200, an adjustable shim 101 for aligning and securing an insertable frame within a receiving frame.

The adjustable shim for aligning and securing an insertable frame within a receiving frame comprises a securing plate 201 having a support surface 202 and a threadably configured inner portion 203. The support surface adapted to support an edge of the insertable frame. A base portion 205 of the adjustable shim 101 having threaded outer portion 206 is arranged in threadable coupling with the threadably configured inner portion 2-3 of the securing plate. The base portion may be adapted for fixed arrangement onto an edge of the receiving frame. A rotation of the securing plate in accordance with the threadable coupling, in one embodiment such as by using a hex head wrench, translates the support surface 202 of the securing plate towards the edge of the insertable frame 102 and away from the edge of the receiving frame 203.

The securing plate is configured to receive an adapter tool and engagement of the adapter tool enables the rotation of the securing plate. In one embodiment, a perimeter 204 of the securing plate comprises a hexagonal configuration and the adapter tool comprises a hexagonal wrench engageable to rotate the securing plate about the threadable coupling.

In one embodiment, the base portion is in concentric arrangement with the support plate, the concentric arrangement including a central channel 208 that allows ingress and egress of a fluid sealant material, such as a sealant foam, that is applied under pressure to a space intermediate the edge of the receiving frame 102 and the edge of insertable frame 103.

In one variation, a shim spacer 209 is arrangeable intermediate the base portion and the edge of the receiving frame. The shim spacer may have a thickness dimension ranging from 1/10 inch to 1 inch to accommodate larger gaps between a perimeter of the insertable frame and an edge of the receiving frame.

In some embodiments, the insertable frame may be such as a window frame, a pre-hung door, and a panel frame.

In yet another embodiment, the base portion may be adapted for fixed arrangement onto an edge of the receiving frame in accordance with one or more screw receiving slots 202, though other fixed arrangement techniques may be used. For example, the base portion may be configured at its base with fastening prongs that can be hammered or forced into engagement with the receiving frame. Direction 211 depicted in FIG. 2 indicates a sequence of assembly of the screws inserted into the screw receiving slots.

In certain embodiments, either one or both of the securing plate and the base portion may be fabricated of any one of a polymer material, a metal, a composite material, or a combination material thereof.

FIG. 3 illustrates, in an example embodiment, method 300 of aligning and securing an insertable frame within a receiving frame using more than one adjustable shims.

At step 310, positioning a first adjustable shim intermediate the insertable frame and the receiving frame, the first adjustable shim being fixedly positioned at a first position along an edge of the receiving frame; and

At step 320, positioning one or more additional adjustable shims intermediate the insertable frame and the receiving frame, the one or more additional adjustable shims being fixedly positioned at respective one or more additional positions along the edge of the receiving frame.

At step 330, upon verifying a level alignment of the insertable frame within the receiving frame, securing the insertable frame in the level position by adjusting the first and at least a second adjustable shims.

In some embodiments, each of the adjustable shims comprise: a securing plate having a support surface and a threadably configured inner portion, the support surface adapted to support the edge of the insertable frame, and a base portion arranged in threadable coupling with the threadably configured inner portion of the securing plate, the base portion adapted for fixed arrangement onto the edge of the receiving frame; and securing the insertable frame is accomplished via a rotation of the securing plate in accordance with the threadable coupling to translate the support surface of the securing plate towards the edge of the insertable frame and away from the edge of the receiving frame.

In an embodiment, the first position and the at least a second position are distally located along the edge of the receiving frame, with a generally maximum dimensional separation therebetween.

In another embodiment, the edge of the receiving frame comprises one of a vertical edge and a horizontal edge. In other embodiments, adjustable shims may be applied at more than one vertical edge of the insertable frame, and also at a bottom horizontal edge of the insertable frame.

The securing plate may be configured to receive an adapter tool, whereby engagement and rotation of the adapter tool enables the rotation of the securing plate.

In one embodiment, a perimeter of the securing plate comprises a hexagonal configuration and the adapter tool comprises a hexagonal wrench that is easily engageable to rotate the securing plate about the threadable coupling.

In another embodiment, the base portion is in concentric arrangement with the support plate. The concentric arrangement may include a central channel that allows ingress and egress of a fluid sealant materia, such as a sealant or thermal insulating foam, that is applied under pressure to a space intermediate the edge of the receiving frame and the edge of insertable frame.

In one variation, a shim spacer is arrangeable intermediate the base portion and the edge of the receiving frame. The shim spacer may have a thickness dimension ranging from 1/10 inch to 1 inch to cater for larger gaps between insertable frame and the receiving frame. The insertable frame may comprise, but not limited to, any one of a window frame, a pre-hung door, and a panel frame, for example. It is contemplated that, in alternate embodiments of the adjustable shim, certain design or physical features of the adjustable shim as described herein with reference to FIGS. 1 and FIG. 2 may be incorporated into aspects of the insertable frame.

The base portion may be adapted for fixed arrangement onto an edge of the receiving frame in accordance with one or more screw receiving slots.

In other embodiments, at least one of the securing plate and the base portion may be fabricated of at least one of a polymer, a metal, a composite material, and a combination thereof.

In other embodiments, the method steps described may be embodied in one or more variations in order of the sequence of steps described herein and with regard to FIG. 3.

It is contemplated for embodiments described herein to extend to individual elements and concepts described herein, independently of other concepts, ideas or system, and also for the embodiments to include combinations of elements recited throughout this application. Although embodiments are described in detail herein with reference to the accompanying drawings, it is contemplated that the invention is not limited to such embodiments. As such, many modifications and variations will be apparent to practitioners skilled in this art.

Accordingly, it is intended that the scope of the invention be defined by the following claims and their equivalents. Furthermore, it is contemplated that a particular feature described either individually or as part of an embodiment can be combined with other individually described features, or parts of other embodiments, even if the other features and embodiments make no specific mention of the particular combination of features. For instance, it is contemplated that certain or most design features of the adjustable shim as a separate component may be integrated into the design of an insertable frame. Thus, any absence of describing combinations should not preclude the inventors from claiming rights to such combinations.