Door Header–Jamb Connection for Fast Alignment and Slip Resistance

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Solution Overview

Problem

Existing door assembly installations require significant time for alignment adjustment of door headers to jambs, and the use of clearance holes for fasteners can lead to load-bearing issues causing slippage in the header-to-jamb connection.

Innovation Solution

A connection system that aligns and secures the header and jamb during installation by using protrusions and receptacles to directly transfer the header's weight onto the jamb, reducing reliance on fasteners and minimizing slippage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If clearance holes are used for fasteners to allow alignment adjustment, then alignment flexibility is improved, but fastener load bearing capacity deteriorates causing slippage

Engineering Contradiction:

Improvealignment adjustment flexibilityVSAvoidfastener load bearing capacity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The connection system is divided into separate functional components: alignment features (protrusions and receptacles) that handle positioning, and fasteners that handle securing. This segmentation allows the alignment function to be optimized independently from the load-bearing function, resolving the contradiction between adjustment flexibility and fastener strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Protrusions and receptacles serve as intermediary elements between the header and jamb. These intermediaries provide the alignment adjustment capability while the fasteners only need to secure the connection, reducing the load requirement on the fasteners and preventing slippage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If traditional fastener connection methods are used, then connection simplicity is maintained, but installation time increases due to alignment adjustment requirements

Engineering Contradiction:

Improveconnection system simplicityVSAvoidinstallation time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The protrusions and receptacles are pre-configured on the header and jamb respectively, establishing the alignment relationship before final fastening. This preliminary alignment setup eliminates the need for time-consuming adjustment during installation, as the components self-align through the protrusion-receptacle engagement.

Inventive Principle:

Principle #10Preliminary action

3Strength

If fasteners are used to connect header and jamb, then connection strength is provided, but slippage occurs under high load bearing conditions

Engineering Contradiction:

Improveconnection strengthVSAvoidslippage resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The connection function is segmented into alignment (protrusions/receptacles) and securing (fasteners). The fasteners only need to prevent withdrawal, not bear the full load, as the protrusion-receptacle mechanical interlock handles the load-bearing function, eliminating slippage under high loads.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connection system combines different mechanical features: protrusions and receptacles provide mechanical interlock for load bearing, while fasteners provide additional securing. This composite approach creates a connection system that is both strong and slip-resistant, overcoming the limitations of fasteners alone.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS20250297514A1Connection system for a header and a jamb of a door assembly

Publication Date: 2025.09.25 SCHLAGE LOCK CO LLC

AI summary

One or more embodiments includes a door assembly with a door jamb and a door header. A connection system is provided that directs the weight of the door header directly into the door jamb. Load on the fasteners is reduced by the connection system along with the potential for slippage for the door header after installation.