Concealable Flush Wall Door Frame Structural Design
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Solution Overview
Problem
Existing flush wall hinged door mounting assemblies suffer from visible gaps between the door and the wall, cracking of plastering material, and lack of structural support, compromising the aesthetic and functional integrity of the door.
Innovation Solution
A concealable structural frame with a frame body comprising a stud facing wall, door facing wall, front surface wall, rear surface wall, and hinge engagement support, designed to be mounted flush with a drywall structure, featuring a stud engaging wall that receives plasterboards and supports hinges, ensuring a concealed appearance and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a known frame assembly is used to mount a flush wall door, then the door can be mounted to the wall structure, but visible gaps appear between the door and wall surface
Solution Approach 1:
The frame assembly is divided into multiple components: a structural frame member with recesses, receiving members for plasterboards, and a separate plaster layer. This segmentation allows each component to fulfill its specific function while collectively achieving the concealed appearance goal.
Solution Approach 2:
Plasterboards and a plaster layer are introduced as intermediary materials between the structural frame and the wall surface. These intermediaries fill the gaps and create a smooth transition, eliminating visible gaps while maintaining structural integrity.
2Shape
If plastering material is applied onto the frame to conceal it, then the concealed appearance is improved, but the plastering material becomes prone to cracking
Solution Approach 1:
The structural frame includes pre-formed recesses and receiving members that are designed to accommodate plasterboards and plaster layers. This beforehand preparation ensures that the plastering material is properly supported and distributed, preventing cracking while achieving the concealed appearance.
3Ease of manufacture
If a non-structural frame is used, then the frame can be easily manufactured and installed, but the peripheral structure must support the door load
Solution Approach 1:
The structural frame is designed to perform multiple functions simultaneously: it provides structural support for the door load, serves as a mounting platform for plasterboards, and creates the necessary geometry for concealed appearance. This multi-functionality eliminates the need for separate structural and cosmetic components.
4Strength
If the frame structure is designed to support door load, then the structural integrity is improved, but the complexity of the frame increases
Solution Approach 1:
The structural support function and the cosmetic frame components are merged into a single integrated structural frame. The frame includes built-in recesses and receiving members that combine load-bearing capabilities with plasterboard accommodation, reducing overall system complexity while maintaining strength.
Data Source
AI summary
A concealable structural frame for mounting a hinged door flushed to a surface of a drywall structure. The concealable structural frame comprises a frame body including a stud facing wall, a door facing wall, a front surface wall, a rear surface wall, a stud engaging wall and a hinge engagement support. The door facing wall is spaced apart from the stud facing wall and includes a door receiving recess. The front surface wall and the rear surface walls are spaced apart and at least partially extend between the stud facing wall and the door facing wall. The stud engaging wall projects outwardly from the stud facing wall and defines a plasterboard receiving recess. The hinge engagement support is positioned between the stud facing wall and the door facing wall and extends along at least a portion of the door receiving recess.