Pocket Door Frame with Universal Header
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Solution Overview
Problem
Current pocket door frames require either complex on-site assembly with skilled labor or costly customization for pre-assembled frames, increasing installation complexity and cost due to the need for tailored components.
Innovation Solution
A pocket door frame design featuring interchangeable vertical supports and adjustable slats, with a universal pre-sized header that can be cut to fit specific door sizes, allowing for easy installation using existing wall studs as a backstop and accommodating various door sizes with an extended header and size indicators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If knocked down door frames are used, then flexibility is improved, but installation complexity and cost increase due to requiring skilled labor for on-site assembly
Solution Approach 1:
The door frame is pre-assembled at the factory with all components (vertical supports, horizontal supports, header, and backboard) prepared and configured before delivery to the installation site. This preliminary assembly eliminates the need for skilled labor to perform complex on-site assembly operations, while the modular design maintains flexibility for different installation scenarios.
2Ease of operation
If pre-assembled door frames with backboard are used, then installation simplicity is improved, but manufacturing cost increases due to need for customization to each door and wall
Solution Approach 1:
The door frame employs standardized components with universal dimensions and configurations that can be applied across multiple door and wall installations. The vertical supports, horizontal supports, header, and backboard are designed as reusable modules that maintain structural integrity and functionality regardless of the specific application, thereby reducing manufacturing complexity and cost while preserving installation simplicity.
3Manufacturing precision
If customized pre-assembled frames are manufactured for each application, then fit and precision are improved, but manufacturing cost and burden increase
Solution Approach 1:
The door frame design incorporates adjustable parameters within standardized component specifications. The universal header and vertical supports can be configured to accommodate variations in door size and wall dimensions through controlled adjustments in component positioning and configuration, rather than requiring complete customization of each frame. This maintains manufacturing efficiency while achieving precise fit for different applications.
Data Source
AI summary
A pocket wall door frame may be provided. The pocket wall doorframe may have vertical supports that hold a plurality of slats. A universal or pre-cut header may be adhered at the top of the vertical supports. A pocket door may be installed in the pocket door frame and may use a stud of the wall as a backstop.