Adjustable Astragal with Modular Link Assembly
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Solution Overview
Problem
Conventional locking astragals for double doors are inflexible and require multiple lengths to accommodate varying doorway heights, necessitating complete disassembly and reassembly for adjustments, which is cumbersome and costly.
Innovation Solution
An adjustable length astragal with a housing containing upper and lower shoot bolts, an actuator, and a connection assembly that adjusts the distance between the actuator and shoot bolts, along with selectively removable interlocking links that allow for length adjustments by adding or removing links, enabling the astragal to fit doors of different heights without full disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional locking astragals are used with fixed lengths, then manufacturing and installation are simplified, but multiple inventory variants are required to accommodate varying doorway heights
Solution Approach 1:
The astragal is divided into multiple modular link segments that can be selectively assembled. Each link is a standardized component with coupling mechanisms, allowing the astragal to be constructed in different lengths by varying the number of links used, thereby eliminating the need for multiple fixed-length inventory variants.
Solution Approach 2:
The astragal transitions from a static fixed-length structure to a dynamic adjustable-length structure. The modular link design with coupling mechanisms enables the astragal length to be modified on-site to match different doorway heights, providing adaptability while maintaining manufacturing simplicity for each individual link component.
2Adaptability or versatility
If adjustable length mechanisms are incorporated into locking astragals, then adaptability to various door heights is improved, but device complexity increases
Solution Approach 1:
By segmenting the astragal into standardized modular links with integrated coupling mechanisms, the complexity is distributed across identical reusable components rather than concentrated in a complex adjustment mechanism. This modular approach simplifies the overall system while enabling adaptability.
Solution Approach 2:
Each modular link serves multiple functions: structural support, connection to adjacent links, and participation in the locking mechanism. This multi-functionality reduces the need for separate adjustment components, thereby limiting the increase in device complexity while achieving adaptability.
3Reliability
If multiple fixed-length astragal variants are maintained in inventory, then proper fit for various door heights is ensured, but inventory costs and storage requirements increase
Solution Approach 1:
Instead of stocking multiple complete fixed-length astragal units, the inventory is segmented into individual standardized link components. A single stock of these universal links can be assembled into any required length, dramatically reducing inventory variety while ensuring proper fit for various door heights.
Solution Approach 2:
The inventory strategy shifts from storing complete units with fixed parameter (length) to storing modular components where the length parameter is determined by assembly configuration. This allows the same component inventory to serve multiple length requirements, reducing total inventory quantity.
Data Source
AI summary
An adjustable length astragal having a housing with an upper shoot bolt and a lower shoot bolt positioned adjacent opposite ends of the housing. An actuator is attached to the housing, connected to and configured to simultaneously extend or retract the upper and lower shoot bolts. An adjustable connection assembly is provided between the actuator and at least one of the shoot bolts. The connection assembly adjusts the distance between the actuator and the respective shoot bolt in each of the shoot bolt's extended and retracted positions.