Cover Plate Assembly Mounting for Plastic Door Frames
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Solution Overview
Problem
The existing method for attaching cover plates to door frames made of plastic hollow profiles is complex and prone to unintentional displacement of assembly elements, leading to incorrect positioning and loss of desired displacement paths, especially when trying to attach displaceable mounting elements to fastening recesses on the door frame.
Innovation Solution
All mounting elements for displaceable fastening are first attached to the cover plate in a non-displaceable manner, forming a cover plate assembly, which is then moved relative to the door frame to connect each mounting element to a fastening recess by a pushing movement parallel to the cover plate plane, ensuring the relative position remains fixed during attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mounting elements are attached to the door frame first and then the cover plate is connected, then the mounting elements can be displaceably fastened to the door frame, but the mounting elements may unintentionally displace during assembly, leading to incorrect positioning and loss of desired displacement paths
Solution Approach 1:
The mounting elements are pre-attached to the cover plate in a fixed, non-displaceable manner before the cover plate assembly is moved to the door frame. This preliminary action ensures that the relative position between mounting elements and cover plate is predetermined and cannot change during the attachment process, eliminating unintentional displacement and ensuring accurate positioning while maintaining ease of assembly through the subsequent single-step attachment to the door frame
2Adaptability or versatility
If multiple separate steps are used to attach mounting elements to the door frame and then connect the cover plate, then displaceable fastening can be achieved, but the production process becomes complex and time-consuming
Solution Approach 1:
The mounting elements and cover plate are merged into a single cover plate assembly where the mounting elements are permanently attached to the cover plate. This merging allows the entire assembly to be moved and attached to the door frame in a single operation, maintaining the displaceable fastening capability while dramatically simplifying the production process and increasing productivity by eliminating multiple separate attachment steps
3Ease of operation
If mounting elements are freely movable during assembly, then they can be displaceably fastened to fastening recesses, but their relative position to the cover plate cannot be ensured, leading to assembly errors
Solution Approach 1:
The relative position between mounting elements and cover plate is predetermined by permanently attaching the mounting elements to the cover plate in advance. This preliminary action ensures that the geometric relationship is fixed and cannot change during assembly, while the displaceable fastening to the door frame is achieved through the subsequent movement and attachment of the entire cover plate assembly to the fastening recesses
Data Source
Figure 1
Figure 1a
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AI summary
The invention relates to a method for manufacturing a door leaf (100) from a door frame formed from several connected hollow plastic profiles (20), wherein at least one cover plate (40) is indirectly connected to the door frame, at least partially, via mounting elements (30) which are immovably connected to the cover plate (40), in particular by a material bond, and which are slidably attached to/in mounting recesses (25) of the hollow plastic profiles (20), wherein all mounting elements (30) provided for the slidable attachment are first immovably attached to the cover plate (40), in particular by a material bond, preferably by adhesive bonding, thereby forming a cover plate assembly (55), after which the cover plate assembly (55) and the door frame are moved towards each other by relative movement perpendicular to the plane of the cover plate (40).in particular until contact is made between the cover plate assembly (55) and the door frame, and each of the mounting elements (30) is slidably connected to a fastening recess (25) by at least one thrust movement parallel to the plane of the cover plate (40). The invention also relates to a mounting element, a cover plate assembly and a set for forming a door leaf.