Bendable Door Hanger Bracket for Wall Thickness Adaptation
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Solution Overview
Problem
Existing door assembly hanger brackets fail to effectively accommodate variations in wall thickness and alignment, often requiring multiple specialized components and complex installation processes, and may not be compatible with standard door trims or wall types.
Innovation Solution
A manually bendable door hanger bracket with a preformed elongated body featuring a first wall mounting tab and a second wall mounting tab, formed by bending along designated lines, allowing for secure attachment to both sides of the wall, regardless of wall thickness or alignment, using a galvanized steel or similar material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional door hanger brackets are used, then installation is possible, but they fail to accommodate variations in wall thickness and alignment, requiring multiple specialized components and complex installation processes
Solution Approach 1:
The bracket is designed with a single elongated body that can be bent to form wall mounting tabs on both sides, allowing one component to perform multiple functions: attaching to the door jamb and mounting to walls of varying thicknesses and alignments. This eliminates the need for multiple specialized brackets for different wall conditions.
Solution Approach 2:
The bracket includes a bendable portion that allows the installer to manually bend the elongated body to form wall mounting tabs at appropriate angles and positions. This dynamic adjustment capability enables the bracket to adapt to various wall thicknesses and alignments, transforming a static component into an adaptable solution.
2Adaptability or versatility
If manually bendable brackets are used, then adaptability to wall variations is improved, but the bracket body must be sufficiently long to extend beyond the door jamb width for bending
Solution Approach 1:
The bracket body is segmented into distinct functional portions: a door jamb mounting portion with mounting holes, a bendable portion for forming wall mounting tabs, and sufficient elongated length to extend beyond the door jamb width. This segmentation allows each portion to perform its specific function while optimizing the overall bracket design.
3Ease of manufacture
If preformed brackets without bend lines are used, then manufacturing is simpler, but forming crisp right-angle corners for stable attachment becomes difficult
Solution Approach 1:
Bend lines are preformed in the bracket body during manufacturing to indicate where the bracket should be bent. These preformed bend lines guide the installer to create crisp right-angle corners at the correct positions, ensuring stable attachment while maintaining manufacturing simplicity through stamping or forming processes.
Data Source
AI summary
A door assembly, a hanger bracket therefor which comprises an elongated manually bendable body which extends from a first wall mounting tab at one end, for a distance approximately equal to the width of a door jamb, and sufficiently far beyond to provide for forming a second wall mounting tab. The elongated body includes at least one bend line extending laterally with respect to the length of said body, whereby the body can be manually bent to form said second wall mounting tab, after the bracket has been secured to the jamb of the door assembly and the door assembly located in the door opening of the wall and secured to one side of the wall by the first wall mounting tab. Two bend lines are shown such that the bracket can be used in a wall having drywall on both sides, or in a wall having drywall on only one side.