Notched Box Head Connector for Low Profile Drywall Installation
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Solution Overview
Problem
Existing connectors for joining headers to vertical uprights in buildings often result in a high surface profile, leading to dry-wall build-up issues and require multiple fasteners, which are not adaptable to different member sizes, limiting their efficiency and versatility.
Innovation Solution
A connector design featuring a notched or coped section that engages the side surfaces of both members without overlying the flaring lower portion, allowing for minimal surface profile and accommodating various member sizes through strategically arranged fastener openings, ensuring a strong connection with reduced fastener usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional L-shaped bracket with side flange is used to connect header to vertical stud, then the connection strength is improved, but the surface profile becomes high causing dry-wall build-up
Solution Approach 1:
The side flange that causes the high surface profile is removed from the connector design. The patent uses a simple L-shaped bracket without the protruding side flange, allowing drywall to be installed flush against the vertical stud without build-up issues, while maintaining connection strength through proper fastener placement.
Solution Approach 2:
Instead of adding a side flange to enhance connection (which causes build-up), the invention inverts the approach by using a minimal-profile L-shaped bracket that achieves connection strength through strategic fastener positioning and geometry, eliminating the need for the problematic side flange structure.
2Ease of manufacture
If a connector with fixed fastener opening positions is used, then the manufacturing simplicity is improved, but the adaptability to different member sizes is reduced
Solution Approach 1:
The connector is designed with multiple rows of fastener openings at different positions, allowing a single standardized connector design to accommodate various stud widths (15⁄8″, 2″, 21⁄2″, 3″, and 31⁄2″) and header sizes. This universal design maintains manufacturing simplicity while providing versatility across different building configurations.
Solution Approach 2:
The fastener opening configuration allows dynamic adaptation to different member sizes by selecting appropriate opening positions. The connector can be installed with fasteners placed in different rows depending on the specific stud and header dimensions, providing flexibility without requiring multiple specialized connector designs.
3Reliability
If multiple fasteners are used to ensure connection strength, then the reliability is improved, but the device complexity and fastener count increase
Solution Approach 1:
The connector provides multiple rows of fastener openings, allowing the use of more fasteners than the minimum required for basic connection. This enables optimization of connection reliability by installing additional fasteners when needed for higher loads or larger members, while still maintaining a simple base design that can use fewer fasteners for standard applications.
Data Source
AI summary
A connector is provided that minimizes the surface profile of a connection between a header and a vertical member. The portion of the connector that engages the side surface of the vertical member and the horizontal member has a notched section such that the connector does not over-lie the flaring lower portion of the header.