Compact Adjustable Pocket Door Frame with Collapsible Transverse Braces
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Solution Overview
Problem
Existing prefabricated pocket door frames are not fully collapsible, leading to high shipping, storage, and retailing costs due to their non-compact packaging.
Innovation Solution
A preassembled pocket door frame design featuring vertically extending members, a horizontally extending upper member, and transverse braces with moveable couplers that can be collapsed into a compact state, allowing for easy installation and reduced packaging size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If prefabricated pocket door frames are designed to be adjustable in width, then they can accommodate various door opening widths, but they cannot be fully collapsed resulting in significant shipping and storage costs
Solution Approach 1:
The pocket door frame is divided into multiple separable components including vertical members, horizontal members, and transverse braces that can be detached from one another. This segmentation allows each component to be independently collapsed and packaged in a compact configuration, reducing overall packaging volume while maintaining adjustable width capability through selective assembly of components.
Solution Approach 2:
The frame incorporates moveable couplers that enable the transverse braces to transition between extended positions (providing structural support and width adjustment) and retracted positions (minimizing packaging volume). This dynamic mechanism allows the same structure to serve dual purposes: maintaining structural integrity during use and achieving compact form during storage and shipping.
2Volume of moving object
If prefabricated pocket door frames are designed to be fully collapsible, then shipping and storage costs are reduced, but installation complexity increases
Solution Approach 1:
The frame components are pre-assembled into partially configured modules at the factory before shipping. The vertical members come pre-attached to horizontal members, and the transverse braces are pre-configured with their moveable couplers. This preliminary assembly reduces the number of individual connection operations required onsite, simplifying the installation process while maintaining the ability to collapse components for compact packaging.
Solution Approach 2:
Moveable couplers serve as intermediary mechanisms that simplify the connection and disconnection of transverse braces to the main frame structure. These couplers provide intuitive attachment points that reduce installation complexity, allowing workers to quickly assemble and disassemble the frame without requiring complex fastening operations, thereby facilitating both easy installation and compact collapsing.
Data Source
AI summary
It is contemplated that the present invention provides a preassembled pocket door frame including a first vertical member, a second vertical member, an intermediary member having a vertically extending central slot, an upper member horizontally extending between the first vertical member and the second vertical member, and at least a pair of transverse braces, each transverse brace extending horizontally between the intermediary member and the second vertical member, each transverse brace having a moveable coupler operable such that each transverse brace is movable from a first, stowed position to a second, generally orthogonal position.