Pre-wired Door Frame with AC/DC Converter

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Solution Overview

Problem

Existing exterior and interior doors for residential and commercial buildings lack integrated power systems, leading to cumbersome and costly retrofits for electrified devices, and existing solutions often clash with aesthetics and require frequent battery replacements.

Innovation Solution

A pre-wired door system with an AC/DC converter and pre-wired receptacles in the door frame, allowing easy integration of electric devices and a centralized power supply, reducing the need for separate power sources and battery replacements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electric devices are added to existing doors as separate add-ons with batteries, then door functionality is enhanced, but installation complexity and maintenance burden increase

Engineering Contradiction:

Improvedoor functionalityVSAvoidinstallation and maintenance

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate electric devices (smart lock, video doorbell, door sensor, etc.) into an integrated door system with a unified power supply unit and control board. This merging eliminates the need for separate batteries in each device, reducing maintenance burden while maintaining enhanced functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The door system is designed as a universal platform that can accommodate various electric devices through standardized mounting locations and a centralized power supply. The system provides multi-functionality through a single integrated unit rather than requiring separate battery-powered devices for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Extent of automation

If battery-powered electric devices are mounted on doors, then door automation is achieved, but aesthetic appearance deteriorates due to visible batteries and housings

Engineering Contradiction:

Improvedoor automationVSAvoidaesthetic appearance

Core Design Contradiction:

Extent of automationVSShape

Solution Approach 1:

The patent extracts the power supply and control components from the visible door surface and relocates them to the door frame or interior cavities. This extraction eliminates the need for visible battery housings on the door exterior, maintaining aesthetic appearance while preserving automation functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The control board and electronic components are nested within the door frame structure or interior cavities, with only necessary interface elements visible on the door exterior. This nesting approach maintains a clean aesthetic while housing all automation components.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Adaptability or versatility

If power lines are brought to the door for supplying power, then powered door functionality is enabled, but installation cost and coordination complexity increase

Engineering Contradiction:

Improvepowered door functionalityVSAvoidinstallation cost and coordination

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent incorporates power supply wiring and receptacles into the door frame during the initial construction phase, before the door is installed. This preliminary action eliminates the need for later coordination with electricians and carpenters, reducing installation complexity and cost while enabling powered door functionality.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If electric devices are retrofitted to existing doors, then door智能化 is achieved, but structural integrity and insulation performance are compromised

Engineering Contradiction:

Improvedoor智能化VSAvoidstructural integrity and insulation

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent integrates electric devices into specific localized areas of the door frame and door assembly where they do not interfere with the overall structural integrity or insulation performance. The power supply unit and control components are positioned in locations that maintain the door's thermal and structural properties.

Inventive Principle:

Principle #3Local quality

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

Facilitates easy installation and maintenance of smart devices while maintaining structural integrity, insulation, and aesthetics, eliminating the need for frequent battery replacements and reducing installation costs.

Implementation Method 1

an AC/DC converter configured to be electrically connected to an AC power unit operably associated with the door system

Methodology Applied

Scientific EffectAC/DC conversion: Rectenna

Data Source

PatentUS20250297515A1Door system with outer door frame pre-wired with ac electrical power for connection with DC power supply unit, and related methods of use, installation, and fabrication

Publication Date: 2025.09.25 MASONITE CORP

AI summary

A door system comprises a door frame adapted to be mounted within an opening, a door pivotally attached to the door frame, an AC/DC converter configured to be electrically connected to an AC power unit operably associated with the door system, a slot in the door system, a pre-wired receptacle disposed in the slot, and an electric device removably disposed in the pre-wired receptacle and electrically connected to the AC/DC converter or the AC power unit through the electrical connector of the pre-wired receptacle.