Double Egress Door Frame Header With Twist-Lock Tabs
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Solution Overview
Problem
The conventional construction of a double egress door frame header from two standard header sections requires skilled labor, is time-consuming, and necessitates heavier material to prevent warping due to welding heat, making the process inefficient and material-intensive.
Innovation Solution
A single channel-shaped header member with a central web and offset slots is used, where separate elongated channel-shaped door stops are attached via tabs that engage the slots and are secured with spot welds, allowing for a lighter gauge steel construction and simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two standard header sections are welded together to form a double egress door frame header, then door stops for opposite swinging doors can be achieved, but the process is time-consuming, requires skilled labor, and necessitates heavier material to prevent warping
Solution Approach 1:
The header is divided into separate modular components: a main header body and detachable door stop sections. Each door stop can be independently attached to the header using tabs that engage with slots in the header, allowing for easy assembly and disassembly without welding operations.
Solution Approach 2:
The door stops are pre-formed as separate components with attachment tabs already integrated. These pre-prepared components are then simply attached to the header in the correct positions, eliminating the need for skilled workers to perform complex welding and alignment operations during final assembly.
2Adaptability or versatility
If two standard header sections are welded together, then door stops can be formed, but heavier material is required to withstand welding heat warping
Solution Approach 1:
By separating the door stop function into independent attachable components rather than forming them by welding header sections together, the header can be made from lighter material that is not subjected to welding heat and subsequent warping issues.
Solution Approach 2:
Tabs serve as intermediary attachment elements that connect the door stops to the header without requiring welding. These tabs engage with slots in the header and can be secured with minimal fastening, eliminating the need for heavy material to resist welding-induced thermal stress.
3Adaptability or versatility
If two header sections are welded together, then door stops are achieved, but the process requires skilled labor and is time-consuming
Solution Approach 1:
The manufacturing process is simplified by producing the header and door stops as separate standard components that can be independently manufactured using conventional forming processes, then easily assembled together without requiring skilled welding operations.
Solution Approach 2:
The tabs on the door stops are designed to self-align and engage with the slots in the header during assembly. The tabs can be twisted or bent to lock into place, providing a self-securing mechanism that does not require skilled labor for proper installation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces material usage, simplifies the manufacturing process, and minimizes the need for skilled labor, while ensuring a stable and secure door frame with reduced warping risks.
Implementation Method 1
the tabs are twisted so that the tabs cannot pull through the slots and thereby hold the channel-shaped door stop members in place
Implementation Method 2
For added security, spot welds are made to connect the bent tabs to the central web
Data Source
AI summary
A double egress door frame has a channel-shaped header with upstanding sides connected by a central web. The central web has a first series of slots that are offset to one side of the central web and a second series of slots that are offset toward the opposite side of the central web. Door stops comprise a right elongated channel-shaped member and a left elongated channel-shaped member. The channel-shaped members are attached to the central web of the header by tabs extending from the sides of the channel-shaped members. The tabs engage the slots. Once the tabs have passed through the slots to the opposite side of the central web, the tabs are twisted thereby connecting the channel-shaped members to the central web. A spot weld is used to insure the door stops is permanently locked into position.