Adjustable Hinge Mounting System for Door Alignment
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Solution Overview
Problem
The installation of continuous hinges and butt hinges often faces challenges due to misalignment issues caused by discrepancies in manufacturing tolerances and the lack of standardization in door and frame cutouts, leading to inadequate clearances and increased reliance on installer skill levels, especially in retrofit situations where doors and frames may be damaged or of varying conditions.
Innovation Solution
The introduction of a hinge system with vertically and horizontally adjustable mounting holes, including conventional round holes and slotted holes, allows for precise alignment and adjustment of doors during installation, enabling secure and proper positioning without extensive pre-positioning, accommodating various door and frame conditions and reducing reliance on installer expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fixed mounting holes are used in hinge installation, then the hinge structure is simple and manufacturing is easy, but misalignment occurs due to manufacturing tolerances and door/frame variations
Solution Approach 1:
The hinge mounting system transitions from fixed static mounting holes to adjustable dynamic mounting holes that can be repositioned vertically and horizontally. This allows the mounting holes to adapt to variations in door and frame dimensions and alignment, resolving the contradiction between manufacturing precision and device complexity by introducing adjustability rather than requiring complex precision manufacturing.
Solution Approach 2:
The mounting holes are designed with adjustable parameters including vertical position, horizontal position, and orientation angle. These parameter changes enable the hinge to accommodate manufacturing tolerances and door/frame variations without requiring complex alignment procedures, thus improving alignment precision while maintaining relatively simple hinge structure.
2Manufacturing precision
If precise marking and drilling is performed during hinge installation, then proper door alignment can be achieved, but installation time increases and reliance on installer skill level increases
Solution Approach 1:
The hinge mounting holes are pre-configured with adjustable features that allow installers to quickly position and secure the hinge without extensive marking and drilling procedures. The adjustability is built into the hinge structure itself, performing the alignment function in advance rather than requiring precise field measurements and markings during installation.
Solution Approach 2:
The adjustable mounting holes enable the hinge to self-align to the door and frame, reducing the need for installer skill and time-consuming manual alignment procedures. The hinge essentially performs its own alignment function through the adjustable mounting features, improving installation speed while maintaining alignment accuracy.
3Strength
If through-bolting with large holes is used for hinge attachment, then strong mechanical connection is achieved, but misalignment occurs frequently due to hole placement difficulties
Solution Approach 1:
The mounting holes are designed as adjustable rather than fixed, allowing the hinge to accommodate variations in door and frame dimensions. This dynamic adjustment capability maintains strong mechanical connections through proper bolt placement while eliminating the misalignment problems associated with fixed large-diameter through-bolts.
Solution Approach 2:
The hinge incorporates different types of mounting holes (vertical slots, horizontal slots, round holes) at different locations to provide localized adjustment capabilities. This allows precise positioning of fasteners at critical locations while maintaining overall hinge strength, resolving the contradiction between attachment strength and hole placement accuracy.
4Adaptability or versatility
If retrofit installation is performed on damaged or varied door conditions, then existing door problems can be addressed, but alignment and mounting become significantly more difficult
Solution Approach 1:
The adjustable mounting holes with multiple position options (vertical slots, horizontal slots, round holes) enable the hinge to adapt to various door conditions including damaged areas and non-standard dimensions. This parameter adjustability provides retrofit capability while keeping the installation procedure relatively simple compared to conventional fixed-hole hinges.
Solution Approach 2:
The hinge mounting system is designed to serve multiple functions: it can accommodate new installations and retrofits, work with various door and frame conditions, and provide both precise alignment and strong attachment. This multi-functionality enhances adaptability while the integrated design keeps overall complexity manageable.
Data Source
AI summary
A hinge including leaves configured to facilitate adjusting the mounting position between hinged objects. In one embodiment, the hinge may generally include first and second leaves pivotally connected together. The leaves define mounting holes that receive fasteners to mount the leaves to the hinged objects. The mounting holes are preferably configured to provide adjustment of the leaves and hinged objects in at least two directions, which may be horizontal and vertical. In one embodiment, the hole shapes preferably may include horizontal slots, vertical slots, round holes, and combinations thereof. Other shapes may be used. When a fastener is partially inserted into a hinged object through a slotted-type mounting hole, for example, the hinged object is slideable relative to the leaf and the other hinged object. By employing a preferred sequence of installation steps, the installer may readily optimize the alignment between and mounting of the hinged objects. In one embodiment, the hinged objects may be a door and a door frame. A method of installation using the specially-configured leaves is also provided.