Adjustable Header Assembly for Variable Wall Stud Spacing

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Solution Overview

Problem

Prefabricated headers in the construction industry often fail to fit openings due to measurement errors, requiring on-site customization and increased costs, as their fixed lengths do not accommodate variations in the distance between vertical wall studs.

Innovation Solution

An adjustable header system comprising two pieces of material and brackets, where one piece has a fixed length and the other is adjustable, allowing for secure attachment to wall studs with fasteners, enabling the header to fit various opening sizes without the need for extensive on-site measurement and cutting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If prefabricated headers with fixed lengths are used, then manufacturing efficiency is improved, but adaptability to different opening sizes deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidadaptability to different opening sizes

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The header is divided into multiple modular sections that can be connected together. Each section has standardized dimensions for efficient manufacturing, while the number of sections can be varied to achieve different total lengths, thus resolving the contradiction between manufacturing efficiency and adaptability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The header incorporates adjustable components such as telescopic sections or extendable elements that allow the length to be modified after manufacturing. This enables a single prefabricated header design to adapt to various opening sizes without requiring custom manufacturing for each size.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If on-site measuring and cutting is performed, then adaptability to different opening sizes is improved, but installation time and labor costs increase

Engineering Contradiction:

Improvefit to actual opening dimensionsVSAvoidinstallation time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The header is pre-assembled in modular sections or with adjustable mechanisms prepared in advance at the manufacturing stage. This preliminary preparation eliminates the need for time-consuming on-site measuring and cutting, as the header can be quickly configured to match the actual opening dimensions through simple assembly or adjustment operations.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If measurement errors occur during planning or installation, then prefabricated headers cannot fit the openings, but rework and additional costs are incurred

Engineering Contradiction:

Improveprefabrication capabilityVSAvoidfit accuracy

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The header design incorporates adjustable parameters such as variable section lengths, extendable elements, or modular configurations that can be adjusted to compensate for measurement variations. This allows the header to maintain fit accuracy despite minor deviations in actual opening dimensions from the planned dimensions.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11619046B2Adjustable header

Publication Date: 2023.04.04 SESSLER JON

AI summary

An adjustable header assembly includes a first piece of material and a second piece of material and at least one bracket. The first piece of material has a fixed length and the second piece of material has an adjustable length. In operation, the length of the second piece of material is adjusted until the second piece of material is proximate wall studs. The second piece of material is then coupled to the studs and the at least one bracket is coupled to the first and second pieces of material.