Door Frame Assembly with Concealed Fasteners for Post-Drywall Installation
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Solution Overview
Problem
Existing door frame assemblies face challenges with coordination, quality alignment, and missing components, leading to delayed construction schedules and lengthy installation times, especially when hollow metal frames are delayed or require finish work post-installation.
Innovation Solution
A door frame assembly design that includes a hinge jamb, lock jamb, and frame head jamb, which can be installed post-drywall with existing studs and walls, featuring trim pieces that overlay and cover fasteners, allowing for quick assembly and adjustment, and a trim attachment bracket for secure fastening, enabling rapid installation and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If door frame assemblies are supplied separately in multiple shipments and assembled on site, then flexibility in installation timing is improved, but coordination problems, quality alignment issues, and missing components occur leading to delayed construction schedules
Solution Approach 1:
The patent combines the door frame assembly with pre-hung doors into a single integrated unit that is shipped together and installed as one complete assembly. This merging eliminates the coordination problems and missing components that occur when frames and doors are supplied separately, while maintaining the flexibility to install after wall completion.
Solution Approach 2:
The door frame assembly is pre-assembled with doors attached before shipping to the job site. This preliminary action ensures all components are present and properly aligned, eliminating on-site coordination issues and quality alignment problems that delay construction schedules.
2Ease of operation
If hollow metal frames are installed prior to wall completion, then installation flexibility is improved, but delivery delays impact the overall construction schedule and wall completion is delayed
Solution Approach 1:
The door frame assembly is designed to be installed after wall completion by incorporating drywall-friendly installation methods. The assembly includes integrated drywall anchors and mounting mechanisms that allow installation through finished walls without requiring prior wall completion, eliminating the time loss from delivery delays impacting wall schedules.
3Adaptability or versatility
If knock-down frames are used for post-drywall installation, then installation timing flexibility is improved, but the ability to ship with pre-hung doors is lost
Solution Approach 1:
The patent merges the door frame with pre-hung doors into a single integrated assembly that maintains structural integrity for shipping while enabling post-drywall installation. The integrated design includes concealed fastening mechanisms that allow the assembly to be installed after drywall completion without requiring knock-down construction, thus maintaining assembly completeness.
4Ease of manufacture
If traditional door frame assemblies require finish work such as taping, sanding, and painting after installation, then structural installation is simplified, but installation time increases to 1-2 hours
Solution Approach 1:
The door frame assembly arrives pre-finished with all necessary surface treatments, trim pieces, and hardware pre-assembled. This preliminary finishing action eliminates the need for post-installation taping, sanding, and painting, reducing installation time from 1-2 hours to approximately 10 minutes while maintaining manufacturing quality.
Solution Approach 2:
The patent combines all finish work elements (trim pieces, moldings, hardware) into the integrated door frame assembly before shipping. This merging eliminates the need for separate finish work steps after installation, dramatically increasing installation speed while maintaining the simplicity of structural installation.
Data Source
AI summary
A welded door frame assembly including a hinge jamb joined to a lock jamb via a frame head jamb, all of which are joined with existing studs and an existing wall. The hinge jamb has a bottom end and a top end and includes a door side base, a door contact flange, and a non-door side trim attachment track including one or more fastener holes. A hinge jamb trim piece includes a connector portion configured to be removably retained within the non-door side trim attachment track and is adapted to cover the non-door side trim attachment track, any fastener holes, and any fasteners. Both the lock jamb and frame head jamb include a door side base, a door contact flange, and a connection flange including one or more fastener holes. A lock jamb or frame head jamb trim piece covers the connection flange, any fastener holes, and any fasteners.