Adjustable Door Frame Mounting Bracket for Construction
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Solution Overview
Problem
The installation of steel door frames in buildings is labor-intensive, requires multiple components, and is prone to damage and inefficiency due to complex logistics and adaptability issues with various construction types, leading to increased costs and inefficiencies in the construction industry.
Innovation Solution
An improved method and apparatus for mounting a door frame using adjustable mounting brackets with integrated pins, a door support frame with soffit and bracket engaging portions, and a trim frame, which simplifies the installation process by reducing the number of parts and manufacturing steps, and allows for adaptable installation in various construction applications, including CMU and hospital settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If welded steel door frame systems are installed during wall construction, then the door frame is installed early in the construction process, but the steel door frames are susceptible to damage from construction activities taking place in and around the door openings
Solution Approach 1:
The door frame system is divided into multiple components: a header, a pair of jambs, and mounting brackets. These components can be assembled into a knock-down configuration for later installation, protecting them from construction damage while allowing delayed installation when the opening is ready.
Solution Approach 2:
The mounting brackets are pre-installed on the wall during wall construction, but the actual door frame components are not assembled into the opening until later. This preliminary preparation allows the frame to be installed after construction activities are complete, avoiding damage while maintaining scheduling flexibility.
2Loss of time
If steel door frames are installed early in the construction process, then the installation takes place well in advance of door and door hardware installation, but multiple deliveries to the construction site are required due to the multiple component nature
Solution Approach 1:
The door frame is segmented into a header, jambs, and mounting brackets that can be supplied as separate components or pre-assembled in a knock-down configuration. This segmentation allows all components to be delivered together in a single shipment while enabling flexible installation scheduling.
Solution Approach 2:
The mounting brackets serve multiple functions: they are installed during wall construction, provide attachment points for the door frame components, and enable later assembly of the complete frame. This multi-functionality reduces the need for separate deliveries of mounting hardware.
3Adaptability or versatility
If multiple components are used to assemble the steel door frame, then the door frame can be adapted to various construction types, but the site logistics become difficult with numerous components requiring storage and movement
Solution Approach 1:
The mounting brackets are designed as universal components that can be installed on various wall types including wood stud, metal stud, and masonry walls. This universality provides adaptability to different construction types while maintaining a simple two-component system that minimizes logistics complexity.
Solution Approach 2:
The mounting brackets are extracted as separate, simple components from the overall door frame assembly. This extraction simplifies the system by separating the wall attachment function from the door frame structure, reducing the number of complex parts while maintaining versatility.
4Strength
If welded steel door frame systems are used, then high-strength and long service life are achieved, but the installation is labor intensive and requires complex logistics processes
Solution Approach 1:
The door frame is segmented into lightweight components (header, jambs, mounting brackets) that can be easily handled and installed. The mounting brackets provide strong wall attachment while the separate components reduce installation labor compared to installing a complete welded frame, yet the assembled structure achieves comparable strength.
Solution Approach 2:
The mounting brackets serve as intermediary components that provide the strong wall attachment traditionally achieved through welded frames. These brackets act as mediators between the wall structure and the door frame components, delivering the necessary strength while simplifying the installation process.
Data Source
AI summary
The present invention provides an improved method and apparatus for mounting a door frame into a door opening of a building and includes at least one mounting bracket, a door support frame, and a trim frame. The at least one mounting bracket is connectable to the door opening and provides mounting pins for engaging the door support frame. The door support frame provides a bracket connecting portion and a soffit engaging portion that are integrally constructed and connected to a soffit of the door support frame. The trim frame is adjustably connected to the door support frame by engaging the bracket engaging portion and the soffit engaging portion of the door support frame.