Split Doorjamb Kit for Reduced Transport Volume
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Solution Overview
Problem
The high costs and logistical challenges of transporting and storing pre-hung doors due to their large thickness, which limits stacking capacity and requires significant storage space, and the issue of trim pieces getting lost or damaged during transit.
Innovation Solution
A pre-hung door unit is provided in kit form with a partially preassembled split doorjamb assembly, where the door is arranged within a space defined by the side and header bases, and extensions are stowed within the cavity, reducing overall thickness for easier transportation and storage, and can be assembled on-site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-hung doors are transported as complete assemblies, then installation ease is improved, but transportation cost and storage space increase due to large thickness
Solution Approach 1:
The door assembly is divided into separate components: the door slab, doorjamb assembly, and trim pieces are packaged individually in separate cartons rather than as one complete pre-assembled unit. This segmentation reduces the overall volume required for transportation and storage while allowing for easy on-site assembly.
Solution Approach 2:
Trim pieces and smaller components are nested within the doorjamb assembly cartons or attached to the door slab packaging. This nesting approach maximizes space utilization during transport by placing smaller items inside or alongside larger components, reducing total transportation volume.
2Productivity
If pre-hung doors are stacked or positioned adjacent one another, then transportation capacity is improved, but the limited stacking capacity due to thickness reduces productivity
Solution Approach 1:
By segmenting the door system into separately packaged components (door slab, doorjamb, trim pieces in individual cartons), the vertical stacking height is significantly reduced. Multiple door units can be stacked on top of each other without the cumulative thickness issue of pre-assembled units, thereby increasing transportation capacity and productivity.
3Adaptability or versatility
If trim pieces are shipped separately in cardboard cartons, then adaptability is improved, but reliability decreases due to risk of loss or damage during transit
Solution Approach 1:
Trim pieces are merged with the doorjamb assembly packaging system. The trim pieces are either attached to the doorjamb assembly within the same carton or securely fastened to the door slab packaging. This merging ensures that all components remain together during transit, eliminating the risk of loss or separation while maintaining packaging flexibility.
Solution Approach 2:
Trim pieces are nested within the doorjamb assembly carton or secured inside the door slab packaging. This nesting approach keeps smaller trim components protected within the larger component packaging, preventing loss and damage during transportation while allowing for adaptable packaging configurations.
Data Source
AI summary
A door unit in kit form includes a partially preassembled split doorjamb assembly, a door, and extensions. The partially preassembled split doorjamb assembly includes first and second side bases substantially parallel to one another and a header base substantially perpendicular to and interconnecting the first and second side bases. The door is arranged within a space defined by the first and second side bases and the header base of the partially preassembled split doorjamb assembly so that the door, the first and second side bases, and the header base collectively establish a cavity. The first and second side extensions and a header extension are unassembled with respect to and connectable lengthwise to the first and second side bases and the header base, respectively. The extensions may be stowed within the cavity and/or stored on outer surfaces of the bases.