Modular Composite Door Frame Kit for Variable Wall Thickness
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Solution Overview
Problem
Door frame manufacturers face inefficiencies due to the need to produce multiple variants of door frame parts to accommodate varying wall thicknesses, leading to increased labor and material costs, and existing materials are prone to damage in humid environments.
Innovation Solution
A door frame creation kit comprising three components - a first band, a main beam, and a second band in rebated and non-rebated variants, made of composite materials containing thermoplastic polymer, wood dust, resin, and additives, allowing for adjustable installation and moisture resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manufacturers produce multiple variants of door frame parts to accommodate varying wall thicknesses, then the door frame can be adapted to different installation conditions, but the number of parts and materials increases, leading to increased labor and material costs
Solution Approach 1:
The patent applies universality by designing a single main beam with multiple attaching slots that can accommodate different band configurations for various door types (rebated and non-rebated) and wall thicknesses. This allows one main beam design to serve multiple functions across different installation scenarios, reducing the need for multiple specialized parts.
Solution Approach 2:
The door frame is segmented into modular components (main beam and bands) that can be independently manufactured and then assembled. The bands are designed with specific attaching slots that correspond to the main beam's slots, creating a modular system where different combinations can be assembled based on installation requirements without requiring custom parts for each scenario.
2Adaptability or versatility
If manufacturers prepare multiple variants of door frame parts for different wall thicknesses, then the door frame can match various installation conditions, but the manufacturing process becomes excessively labor-intensive and cumbersome
Solution Approach 1:
The main beam is designed as a universal component with multiple attaching slots that can accommodate different band types and configurations. This universal design allows a single manufacturing process to produce a main beam that can be used across multiple application scenarios, eliminating the need for separate manufacturing processes for different wall thickness configurations.
Solution Approach 2:
The design allows for parameter changes in the final assembly by providing bands with different dimensions and attaching slot configurations that can be selected based on wall thickness requirements, while the main beam itself maintains a standardized design. This separates the manufacturing parameter (standardized main beam) from the installation parameter (variable band configurations).
3Adaptability or versatility
If manufacturers store a large amount of materials to provide various door frame variants, then the door frame can be adapted to different installation conditions, but the storage requirements and material management become cumbersome
Solution Approach 1:
The standardized main beam design with multiple attaching slots serves as a universal component that can be used across different door frame configurations. This reduces the inventory requirements from needing to store multiple variants of main beams to storing only one standardized main beam design, while still being able to accommodate various installation conditions through different band combinations.
Solution Approach 2:
The patent merges the functionality of multiple door frame variants into a single standardized main beam design that can be combined with different bands. This consolidation reduces the total quantity of materials that need to be stored and managed, as instead of storing multiple main beam variants, the system stores one main beam type and multiple band types.
4Shape
If door frames are made from wood or plywood to achieve desired aesthetic aspects, then the door frame has good appearance, but the material is highly susceptible to damage when in contact with water or in high humidity environments
Solution Approach 1:
The patent employs composite materials consisting of a plastic base material combined with wood dust or fiber reinforcements. This composite structure provides the aesthetic appearance characteristics of wood while incorporating the moisture resistance and durability of plastic materials, creating a door frame that is both visually appealing and resistant to water and humidity damage.
Solution Approach 2:
The material composition parameters are changed from traditional solid wood or plywood to a composite material system with specific ratios of plastic base material, wood dust, and fiber reinforcements. This parameter change maintains the visual aesthetic properties while fundamentally altering the material's resistance characteristics to water and humidity.
Data Source
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AI summary
The object of the invention is a door frame creation kit, being in a both rebated as well as non-rebated variants, having three parts: a first band, a main beam and a second band, wherein the first band, the main beam and the second band - are made of lignocellulosic materials and composite materials composed of, among other things, thermoplastic polymer, wood dust, resin and additives and fillers, wherein the first band and the main beam have respectively the same construction for use in both rebated and non-rebated variants, wherein the second band constitutes a masking band of the finished frame and in the rebated variant is in the form of an angled piece with one masking arm and a second fastening arm, in the non-rebated variant is in the form of an angled piece with one masking arm and the second fastening arm, whereby on the fastening arm, from the side of the masking arm - there is a distancing thickening.