Pre-hung Door Frame with Planar Track for Corrugated Wall Installation
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Solution Overview
Problem
Existing pre-hung door assemblies struggle with installation on corrugated walls, as conventional frames with flanges do not accommodate non-planar surfaces, leading to costly and time-consuming on-site fabrication using heavy tubular steel, and result in gaps between the flange and the wall.
Innovation Solution
A pre-hung door assembly with a two-piece construction featuring a frame member and a track member, where the track member forms a planar exterior surface to securely install the door frame on corrugated walls, using 16 Gauge steel to reduce weight and facilitate easier installation, and the frame member includes a rabbet and soffit to house the door, with returns defining a throat opening for access and a track member covering the throat to provide a sealed exterior surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional frames with flanges are used for installation, then the door frame can be securely attached to planar walls, but the installation fails on corrugated walls due to non-planar surfaces creating gaps between the flange and wall
Solution Approach 1:
The door frame is divided into two separate components: a frame member that provides structural support and a track member that forms the exterior surface. This segmentation allows each component to perform its specific function - the frame member can be sized appropriately for structural integrity while the track member creates a planar installation surface that accommodates corrugated walls.
Solution Approach 2:
The track member adds a dimensional element by extending from the frame member to create a planar exterior surface. This additional dimension (the track member's length extending perpendicular to the frame member) provides a flat mounting surface that bridges the gap between the door frame and the corrugated wall, effectively adding a new dimensional layer to solve the non-planar attachment problem.
2Adaptability or versatility
If tubular steel is used for on-site fabrication of door frames on corrugated walls, then the door frame can be installed on non-planar surfaces, but the process becomes cost and time prohibitive and the materials become heavy
Solution Approach 1:
The door frame is pre-assembled in a factory setting with the frame member and track member already connected. This preliminary assembly eliminates the need for on-site fabrication of the frame structure itself, reducing installation time and cost. Only the final attachment to the wall is performed on-site, rather than fabricating the entire frame structure at the installation location.
Solution Approach 2:
The door frame uses a composite construction combining the frame member (providing structural support) and the track member (providing the exterior planar surface). This composite structure achieves the adaptability needed for corrugated walls without requiring heavy tubular steel fabrication, as the track member's planar surface can be attached to corrugated walls while the overall structure remains lighter and more efficient.
3Adaptability or versatility
If tubular steel is used for on-site fabrication, then the door frame can be installed on corrugated walls, but the frame becomes heavy and difficult to handle
Solution Approach 1:
The door frame employs a composite structure with a frame member and a track member that work together to provide both structural integrity and adaptability to corrugated walls. This composite design achieves the necessary functionality without requiring the heavy tubular steel construction, resulting in a lighter overall frame that is easier to transport and install.
Solution Approach 2:
By segmenting the door frame into separate frame member and track member components, each can be optimized for its specific function. The frame member provides structural support with appropriate weight, while the track member provides the planar surface for wall attachment. This segmentation avoids the need for heavy-walled tubular steel construction throughout the entire frame, reducing overall weight.
Data Source
AI summary
A steel door frame includes a frame member for hanging a door and a track member that forms an exterior surface of the door frame. The exterior surface of the track member forms a planar surface for being inserted into a rough opening of a corrugated wall in order to facilitate installation.