Segmented Door Hanger Bracket for Wide Jamb Alignment
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Solution Overview
Problem
Existing door hanger bracket technologies face challenges in accommodating variations in wall thickness and alignment, particularly when dealing with pre-hung door assemblies, as they often require complex installations and may not be compatible with standard door trims or provide adequate support for wider door jambs.
Innovation Solution
A door hanger bracket with an elongated, manually bendable body featuring preformed wall mounting tabs and a break line, allowing for secure attachment to door jambs and adjustable mounting on both sides of the wall, enabling flexible use on different jambs or wider door assemblies by separating into two separate brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a standard door hanger bracket is used, then the installation is simple, but it cannot accommodate wider door jambs or variations in wall thickness
Solution Approach 1:
The bracket is designed with a break line that allows it to be divided into two separate brackets. This segmentation enables the single bracket design to accommodate wider door jambs by splitting it into two smaller mounting sections, each capable of being attached to the wall independently, thereby increasing adaptability without requiring multiple different bracket designs.
Solution Approach 2:
The bracket includes bend lines that allow it to be manually bent into different configurations. This dynamic adaptability enables the same bracket to be adjusted for different wall thicknesses and mounting positions, allowing one bracket design to serve multiple installation scenarios without requiring multiple fixed designs.
2Adaptability or versatility
If a pre-hung door assembly with standard brackets is used, then the door and jamb are sold as a single unit, but the installation does not accommodate variations in wall thickness and alignment
Solution Approach 1:
The bracket's bend lines enable manual adjustment during installation to accommodate variations in wall thickness and alignment. This dynamic feature allows the installer to adapt the bracket to the specific wall conditions without requiring complex adjustment mechanisms or multiple specialized brackets, maintaining ease of operation while improving adaptability.
Solution Approach 2:
The bracket allows changes in its physical configuration through bending at designated lines, altering its shape and mounting characteristics to match the specific wall parameters encountered during installation. This enables adaptation to different wall thicknesses and alignments while using a single standardized bracket design.
3Strength
If clips are used to attach the jamb to the wall, then mounting is facilitated, but they require substantial numbers of nails and do not provide adequate support for wider door jambs
Solution Approach 1:
The bracket combines multiple functions into a single component: it provides both the mounting attachment points and the structural support for the door jamb. By integrating the mounting tab and support structure into one piece, the bracket reduces the number of separate fasteners needed while maintaining adequate support capacity for wider door jambs.
Solution Approach 2:
The bracket serves multiple functions simultaneously: it attaches to the wall, supports the door jamb weight, and accommodates wider jamb configurations through its break line feature. This multi-functionality allows a single bracket type to replace multiple specialized components, reducing the total quantity of fasteners and parts required.
Data Source
AI summary
A door assembly, a hanger bracket therefor and the method of using the bracket to hang the door jamb assembly, in which the door hanger bracket has an elongated body configured to provide a wall mounting tab at each end, such that said bracket can be secured to a door jamb as a unitary bracket and provide a wall mounting tab on each wall at each side of the jamb. The bracket also includes a break line such that it can be broken in two and used either on two different jambs or two different locations on the same side of a single jamb or can be located on opposite sides of the same jamb, where the jamb is too wide for the unitary bracket.