Door straightening system and methods of using same

Abstract

A door straightening system for straightening doors includes elongated tension members that extend substantially from a top portion to a bottom portion of the door. The tension members are mechanically strained using an adjustment mechanism that may take the form of threaded components, which when rotated create tension in the tension members sufficient to move the interior and exterior surfaces of the door. The door straightening system may be located in a stile of the door generally within a machined channel or an insert. The door straightening system includes reaction plates that provide the load path between the tension members and the door. In one embodiment, an upper reaction plate is configured to have a desired angle to minimize stress and increase the efficiency of the door straightening system.

1 . A straightening system for a door comprising:
 a tensioning member located within the door;   an upper reaction plate positioned proximate a top portion of the door and seated at a desired angle relative to a horizontal surface of the door;   an adjustment mechanism having a body with a threaded portion and a head with a tool receiving portion, the adjustment mechanism rotatable with respect to the reaction plate to rotate the tensioning member; and   an intermediate coupling member having a threaded portion threadably engaged with the threaded portion of the adjustment mechanism and coupled to the tensioning member.   
     
     
         2 . The straightening system of  claim 1  wherein the tensioning member is an elongated steel rod. 
     
     
         3 . The straightening system of  claim 1  wherein the threaded portion of the adjustment mechanism is located within an elongated bore formed within the body of the adjustment mechanism. 
     
     
         4 . The straightening system of  claim 1  wherein the intermediate coupling member is integrally formed with the tensioning member. 
     
     
         5 . The straightening system of  claim 1  wherein the threaded portion of the intermediate coupling member is a cylindrical rod with external machine threads. 
     
     
         6 . The straightening system of  claim 1  wherein the intermediate coupling member is welded to the tensioning member. 
     
     
         7 . The straightening system of  claim 1 , further comprising:
 a lower reaction plate having a recessed portion to receive the tensioning member.   
     
     
         8 . The straightening system of  claim 7  wherein the bottom plate is seated in a pocket offset from a bottom edge surface of the door. 
     
     
         9 . The straightening system of  claim 1  wherein the door includes a channel formed along a lengthwise portion of the door and located between an interior surface and an exterior surface of the door, the channel extends from approximately the top portion of the door downward toward a bottom edge surface of the door, the channel is sized to closely receive the tensioning member, the adjustment mechanism and the intermediate coupling member. 
     
     
         10 . The straightening system of  claim 1 , further comprising:
 an elongated insert extending from approximately the top portion of the door downward toward a bottom edge surface of the door, the elongated insert located between an interior surface and an exterior surface of the door, the insert sized to receive the tensioning member, the adjustment mechanism and the intermediate coupling member.   
     
     
         11 . The straightening system of  claim 10  wherein a top portion of the elongated insert is coupled to the upper reaction plate. 
     
     
         12 . The straightening system of  claim 1  wherein the desired angle of the reaction plate is in a range of about 1 degree to 30 degrees relative to the horizontal surface of the door. 
     
     
         13 . The straightening system of  claim 1  wherein the desired angle is about 3 degrees relative to the horizontal surface of the door. 
     
     
         14 . The straightening system of  claim 1  wherein the head of the adjustment mechanism is received in a recess located in the upper reaction plate. 
     
     
         15 . A method of straightening a door using a door straightening system, the method comprising:
 rotating a first adjustment mechanism in a first rotational direction to change an amount of tension in a first tension member; and   while rotating, displacing a portion of the door to correct an amount of warping and sufficiently straighten the door.   
     
     
         16 . The method of  claim 15 , further comprising:
 rotating a second adjustment mechanism in a second rotational direction to change an amount of tension in a second tension member.   
     
     
         17 . The method of  claim 15  wherein rotating the first adjustment mechanism in the first rotational direction includes inserting a tool into a corresponding opening of the first adjustment mechanism. 
     
     
         18 . The method of  claim 15  wherein rotating the first adjustment mechanism includes threading the adjustment mechanism relative to a threaded end of an intermediate coupling member that is fixed to the tension member. 
     
     
         19 . The method of  claim 15 , further comprising:
 reacting the amounts of tension in the first tension member through upper and lower reaction plates coupled to the door.