Extruded Door Frame Post With Integrated Weatherproofing Channel

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Solution Overview

Problem

Conventional door frame construction methods are labor-intensive, time-consuming, and lack weatherproofing, requiring significant on-site skill and improvisation for weatherproofing measures.

Innovation Solution

A door frame post and assembly system featuring an extruded longitudinal post member with internal cavities and external channels, accompanied by filler strips and a frame member that can be easily assembled using fasteners, providing a weatherproofing channel and eliminating the need for additional fasteners between components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional wooden side plates and top plates are used for door frame construction, then structural strength is achieved, but labor intensity and construction time increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidconstruction speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The door frame is divided into separate modular components: a plastic post member, a frame member, and a filler strip. These segments can be manufactured independently and then assembled together, allowing for pre-fabrication and reducing on-site construction time while maintaining structural integrity through the interlocking design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines plastic material for the post member with wooden frame members and filler strips to create a composite door frame system. This composite approach leverages the advantages of each material - the plastic provides weather resistance and structural form, while the wood provides strength and aesthetic finish, achieving both speed and strength.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If conventional wooden door frames are constructed on-site, then adaptability to different configurations is achieved, but weatherproofing is insufficient and requires additional work

Engineering Contradiction:

Improveconfiguration flexibilityVSAvoidweatherproofing quality

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The plastic post member is pre-formed with an integrated weatherproofing channel during manufacturing, eliminating the need for on-site weatherproofing work. The channel is already positioned and shaped to receive weather stripping, ensuring proper weatherproofing is built-in before installation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The plastic post member serves multiple functions simultaneously: it provides structural support, contains the weatherproofing channel for weather protection, and includes attachment features for securing the frame member. This multi-functionality integrates weatherproofing into the core structure without sacrificing adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If pre-fabricated plastic door jambs are used, then construction time is reduced and cost is decreased, but structural integrity and assembly complexity must be maintained

Engineering Contradiction:

Improveconstruction speedVSAvoidassembly complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The attachment features and weatherproofing channels are extracted as separate integrated elements from the plastic post member, allowing the frame member and filler strip to be added independently. This extraction simplifies the assembly process by enabling modular installation without requiring complex integration steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The filler strip is inserted into the cavity of the post member, and the frame member is attached to the post member, creating a nested structure. This nesting approach simplifies assembly by allowing components to be added sequentially within the existing structure, reducing overall assembly complexity while maintaining integrity.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of operation

If multiple separate components are used for door frame assembly, then ease of installation is improved, but the number of fasteners and assembly steps increases

Engineering Contradiction:

Improveinstallation easeVSAvoidnumber of fasteners

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The attachment features for securing the frame member are merged into the plastic post member structure itself, eliminating the need for separate fasteners. The integrated attachment features combine the functions of alignment, securing, and weatherproofing into a single component system, reducing the total number of fasteners needed.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8919056B2Door frame post, and door frame assembly comprising same and kit for assembly of same

Publication Date: 2014.12.30 ROCHMAN ODED EDDY

AI summary

A door frame post comprises an extruded, longitudinal post member comprising at least one longitudinal internal cavity and a longitudinal external channel, and a longitudinal frame member matingly engaging the external channel of the post member. One or more longitudinal filler strips are inserted into the at least one internal cavity, each filler strip comprising at least one longitudinal cavity for receiving one or more fasteners.