Adjustable Butt Hinge Inserts for Door Alignment
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Solution Overview
Problem
The existing methods for hanging doors with butt hinges require high accuracy in mortising and drilling, leading to potential misalignment, structural weakness, and aesthetic issues, especially when replacing doors, as they often necessitate new holes and modifications to the existing mortising, increasing time and effort.
Innovation Solution
A butt hinge with adjustable inserts that allow for various attachment configurations, enabling the second leaf to be positioned and angled correctly without requiring new holes or filling existing ones, using a combination of concentric and eccentric inserts for rotatable attachment to the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mortising and drilling methods are used for attaching butt hinges, then the hinge can be securely attached to the door and door frame, but high accuracy is required in mortising and drilling holes, and small margins of error lead to incorrect door hanging
Solution Approach 1:
The patent changes the parameter of attachment hole positioning by providing multiple pre-drilled holes at different positions and angles in the second leaf. This allows the installer to select the most appropriate hole configuration without requiring precise custom drilling, thereby reducing the manufacturing precision requirement while maintaining ease of operation.
Solution Approach 2:
The patent introduces adjustability into the hinge attachment system by allowing selection between multiple fixed hole positions and angles. This dynamic configuration capability enables the hinge to adapt to various installation scenarios, reducing the need for high precision in any single predetermined position.
2Adaptability or versatility
If new holes are drilled in the door frame to replace an existing door, then the hinge can be repositioned, but the old holes require filling and the existing mortising may require modification, reducing structural strength and aesthetics
Solution Approach 1:
The patent applies preliminary action by pre-drilling multiple holes in the second leaf during manufacturing. When replacing a door, the installer can directly use existing holes in the door frame without needing to drill new holes or fill old ones, thereby maintaining structural strength and avoiding aesthetic degradation.
Solution Approach 2:
The patent makes the second leaf universal by incorporating multiple receiving apertures that can accommodate various screw hole patterns. This multi-functionality allows the same hinge leaf to be attached to different door frames with existing holes in various positions, eliminating the need for new hole drilling and preserving structural integrity.
3Adaptability or versatility
If new holes are drilled in the door frame to replace an existing door, then the hinge can be repositioned, but the process significantly contributes to the time and effort required to hang the door
Solution Approach 1:
The patent applies preliminary action by pre-drilling multiple holes in the second leaf during manufacturing. When replacing a door, the installer can directly use existing holes in the door frame without needing to drill new holes or fill old ones, thereby maintaining structural strength and avoiding aesthetic degradation.
Solution Approach 2:
The patent applies preliminary action by providing multiple pre-positioned receiving apertures in the second leaf. This allows the installer to quickly select and use existing holes in the door frame without time-consuming drilling operations, significantly reducing the time and effort required for door replacement.
4Ease of manufacture
If the second leaf has fixed attachment hole positions, then the manufacturing process is simple, but the hinge cannot be adjusted to achieve correct angle and position relative to the surface
Solution Approach 1:
The patent segments the attachment functionality by providing multiple separate receiving apertures in the second leaf, each capable of receiving attachment means. This segmentation allows the hinge to be manufactured simply with fixed hole positions while still providing adjustability, as the installer can select different aperture combinations to achieve the desired angle and position.
Solution Approach 2:
The patent makes the second leaf universal by incorporating multiple receiving apertures that can accommodate various screw hole patterns. This multi-functionality allows the same hinge leaf to be attached to different door frames with holes in various positions, eliminating the need for new hole drilling and preserving structural integrity.
Data Source
AI summary
Several problems may be encountered when hanging a door with a butt hinge. Small margins of error in the alignment of the butt hinge may lead to the door being incorrectly hung. The present invention provides a butt hinge 100 comprising receiving apertures 140 configured to selectively receive first inserts 160 or second inserts 170. The first inserts 160 comprise concentric apertures 165 and the second inserts 170 comprise eccentric apertures 175. Selection and arrangement of the inserts 160, 170 in each of the receiving apertures 140 permits adjustable positioning of attachment means therein, thereby enabling adjustable attachment of the butt hinge 100 to a surface. This makes the process of hanging the door quicker, more straightforward and less susceptible to user error.