Adjustable Door Mounting System With Captive Nut Assembly
Solution Overview
Problem
The existing door mounting systems face difficulties in achieving precise and cost-effective replacement and adjustment of doors within existing frames, particularly due to the complexity of aligning and fitting new doors with varying dimensions and frame conditions, which often requires skilled labor and is costly.
Innovation Solution
An adjustable door and hinge mounting system that includes a user-adjustable captive nut assembly with a movable adjusting plate and holding bracket, allowing for three-dimensional adjustability of doors relative to the frame, enabling vertical, horizontal, and rotational adjustments, facilitating easier installation and alignment without the need for slotted screw holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional door mounting systems are used, then door installation requires skilled labor and precise measurements, but this increases installation cost and time
Solution Approach 1:
The adjusting plates are pre-installed on the door at multiple locations with multiple adjustment holes, allowing the door to be quickly positioned and secured without requiring complex measurements or skilled alignment work during installation
Solution Approach 2:
The adjustment mechanism is divided into multiple discrete adjusting plates with multiple holes each, allowing independent adjustment of different door positions and enabling precise alignment through simple hole-to-bolt matching rather than complex measurement procedures
2Adaptability or versatility
If traditional door replacement is performed, then custom fitting is required for each door, but this increases manufacturing cost and complexity
Solution Approach 1:
The adjusting plates serve multiple functions: they are pre-installed on the door, provide vertical and horizontal positioning, enable rotational adjustment, and work with standard bolts. This universal mechanism allows the same door design to fit various frame sizes and conditions without custom manufacturing
Solution Approach 2:
The adjusting plates incorporate multiple holes that allow the door position to be dynamically adjusted during installation to accommodate variations in frame dimensions and alignment, eliminating the need for custom-fitted doors for each application
3Manufacturing precision
If frame removal and replacement is performed, then proper fitting requires great skill and is extremely costly, but this is necessary to ensure proper door installation
Solution Approach 1:
The adjusting plates replicate the positioning function of traditional custom-fitted frames by providing multiple pre-drilled holes that can be aligned with standard bolts, creating a simplified copy of the precise positioning capability without requiring skilled frame fitting work
Data Source
AI summary
A three-dimensional adjustable door mounting system and method for aligning and installing a hinged door within a frame. In one embodiment, the mounting system includes one or more captive nuts mounted to the door. The captive nut includes a movable adjusting plate retained by a stationary holding bracket mounted to the door. A threaded fastener inserted through a hinge door leaf and into the adjusting plate allows an installer to move and adjust the position of the hinge relative to the door in a first plane. In other embodiments, captive nuts may further be affixed to the door frame. A threaded fastener inserted through a hinge frame leaf and into the adjusting plate allows an installer to move and adjust the position of the hinge and door relative to the frame in a second plane different than the first plane.