Concealed Axis Door Hinge Assembly for Metal Frames
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Solution Overview
Problem
Conventional door hinge systems for metal frames require numerous components, are laboriously adjusted on-site, and do not allow for easy pre-assembly, leading to assembly errors and increased installation time.
Innovation Solution
A modular door hinge arrangement with a concealed axis of rotation, integrated into a metal frame's pocket, allowing for pre-assembly and easy installation, featuring a one-piece door hinge with a single axis of rotation, reducing visible components and enabling automatic assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional door hinge systems are used for metal frames, then the door can be assembled, but a large number of components are required and assembly is complex
Solution Approach 1:
The patent combines multiple separate hinge components (base plate, front plate, rear plate, mounting brackets) into a single integrated door hinge unit. This merging reduces the number of parts that need to be manufactured, stored, and assembled, directly addressing the complexity issue while maintaining all necessary functional elements for securing the door to the metal frame.
Solution Approach 2:
The integrated door hinge unit performs multiple functions simultaneously: it provides structural support, enables rotation, secures the door to the frame, and accommodates the hinge axis. This multi-functionality eliminates the need for separate base plates and mounting brackets, simplifying both manufacturing and assembly processes.
2Ease of operation
If conventional door hinge systems are used, then the door can be assembled, but laborious on-site adjustment is required
Solution Approach 1:
The door hinge unit is pre-assembled and pre-adjusted in the factory before delivery to the construction site. This preliminary action ensures that the hinge is ready for immediate installation without requiring laborious on-site adjustment, significantly reducing installation time and eliminating assembly errors that occur during field assembly.
Solution Approach 2:
The integrated design of the door hinge unit with built-in adjustment mechanisms allows the hinge to self-adjust during installation through simple mechanical operations. The unit includes features that automatically align and position components correctly, reducing the need for manual intervention and complex adjustment procedures on-site.
3Reliability
If conventional door hinge systems are used, then the door can be assembled, but assembly errors occur at the construction site
Solution Approach 1:
By pre-assembling the door hinge unit in the factory with precise alignment and quality control, the patent eliminates the source of assembly errors. The pre-assembled unit arrives at the construction site as a single verified component, ensuring consistent and accurate installation every time without the variability introduced by on-site assembly.
Solution Approach 2:
The integration of all hinge components into a single unit reduces the number of assembly steps and connection points where errors could occur. Fewer separate parts mean fewer opportunities for misalignment, incorrect fastening, or improper installation, thereby improving overall assembly reliability.
4Shape
If conventional door hinge systems are used, then the door can be assembled, but the hinges are visible and less aesthetically pleasing
Solution Approach 1:
The door hinge unit is designed to nest within the door frame structure, with the hinge axis and moving parts concealed inside the frame's hollow profile. This nesting approach hides the mechanical components from external view, providing a clean aesthetic appearance while maintaining all necessary hinge functions within the compact integrated unit.
Data Source
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AI summary
The assembly (20) has a casing fastening device (60) fastening a door hinge unit (50) to a door casing. A leaf fastening device (100) fastens the hinge unit to a door leaf. The hinge unit is designed such that a rotational axis (22) of the hinge unit is positioned in the door casing during closing and opening the door leaf. A door hinge (52) is immersed in a hinge recess of the door casing during closing the door leaf, and masked in a closing position of the leaf. The door hinge is moved out of the recess during opening the door leaf.