Prehung Door Packaging with Protective Side Caps and Spacers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing door packaging solutions for prehung door assemblies are inadequate as they do not provide sufficient protection during shipping and handling, and require the use of wood pallets for unitization.
Innovation Solution
A single unit protective door package that includes a prehung door assembly, upper and lower protective side caps, and support spacers, which are secured with tightening straps, eliminating the need for a wood pallet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cardboard guards are used to protect door assemblies, then some protection is provided, but the protection is insufficient and the guards are not securely retained
Solution Approach 1:
The patent uses composite materials by combining corrugated cardboard with plastic components (retaining rings, straps, and foam inserts) to create a protective guard system that is both cushioning and structurally secure. The plastic retaining rings provide mechanical retention while the cardboard provides cushioning protection.
Solution Approach 2:
The protective guards are formed into curved, contoured shapes that conform to the corners and edges of the door assemblies. This curvature allows the guards to wrap around and securely retain the corners, providing better protection and stability compared to flat cardboard pieces.
2Productivity
If wood pallets are used to hold unitized door packages, then unitization is achieved, but unnecessary packaging material is used and the structure is complex
Solution Approach 1:
The patent merges the protective guard function with the unitization function into a single integrated structure. The protective guards themselves serve as the structural framework for holding multiple door assemblies together, eliminating the need for separate wood pallets and reducing overall packaging complexity.
Solution Approach 2:
The protective guard structure serves multiple functions simultaneously: it protects the door assembly corners from damage, provides structural support for the package, and acts as the framework for unitizing multiple door assemblies. This multi-functionality eliminates the need for separate wood pallets.
3Ease of operation
If loose cardboard guards are used, then ease of application is maintained, but the guards are not tightly retained and provide insufficient protection
Solution Approach 1:
The patent incorporates preliminary retention features directly into the guard structure during manufacturing, such as pre-attached plastic retaining rings and foam inserts. These components are prepared in advance to ensure tight retention when the guard is applied to the door assembly, eliminating the need for complex assembly steps.
Solution Approach 2:
The patent uses flexible plastic retaining rings and strap elements that can be easily applied to the door assembly while providing tight retention. These flexible components conform to the door geometry and maintain secure attachment without requiring rigid, complex structures.
Data Source
AI summary
A single unit protective door package for packaging of a single prehung door assembly. The door assembly comprises a door frame and a door slab pivotally attached to the door frame. The door frame includes right and left side jambs and a head jamb connecting upper ends of the right and left side jambs. The single unit protective door package comprises the door assembly, upper protective side caps each mounted to the door assembly at one of opposite upper corners of the door frame, lower protective side caps each mounted to the door assembly at one of lowermost edges of the door frame, and two support spacers each mounted to one of the lowermost edges of the door frame for elevating a bottom edge of the door slab above the ground to a distance compatible with a forklift, pallet jack or hand truck.