Self-Levelling Door Frame Fastener for Plasterboard Walls
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Solution Overview
Problem
Current fastening elements for swing doors in plasterboard walls do not allow the frame to self-level with the subframe, requiring manual levelling and additional plastering, and are not adaptable to different door opening directions or panel types.
Innovation Solution
A self-levelling support wing integrated into a flattened metal profile that fastens to the upright or subframe, allowing the frame to maintain level alignment and distribute door weight, with additional features for finishing with plasterboard panels without needing additional plaster.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current fastening elements are used to attach the frame to the subframe, then the frame can be fastened to the upright, but the frame cannot self-level with the subframe, requiring manual levelling operations
Solution Approach 1:
The fastening element incorporates an integrated leveling wing that enables the frame to self-level with the subframe automatically during assembly. The wing's geometry and positioning allow the frame to find its own level position without requiring manual intervention or additional leveling tools, thus eliminating time loss while maintaining precision.
Solution Approach 2:
The leveling wing is pre-integrated into the fastening element design, with predetermined geometry and positioning features that automatically establish correct level alignment when the frame is mounted. This preliminary configuration of leveling capability within the fastening element itself eliminates the need for separate leveling operations during assembly.
2Manufacturing precision
If manual leveling and plastering operations are performed to finish wall edges, then proper alignment and appearance are achieved, but significant time is lost in these additional operations
Solution Approach 1:
The fastening element is designed with multiple functions integrated into a single component: it provides structural fastening, self-leveling capability, and built-in finishing surfaces for wall edges. The inclusion of integrated finishing wings eliminates the need for separate plastering operations, as these wings provide the necessary surface for direct panel attachment or finishing.
Solution Approach 2:
The invention merges the fastening function, leveling function, and wall finishing function into a single integrated fastening element. The finishing wings are combined with the fastening structure, allowing the element to simultaneously secure the frame and provide ready-to-finish surfaces for wall panels, eliminating sequential operations.
3Strength
If classic sheet lag screws are used to fasten the frame to the upright, then the frame is attached, but heavy doors cannot be properly supported when open
Solution Approach 1:
The fastening element is segmented into multiple functional components: a main fastening body for attachment to the upright, leveling wings for alignment, and support wings for load distribution. This segmentation allows each component to specialize in its function, with support wings specifically designed to distribute door weight across multiple contact points with the upright, enhancing support reliability for heavy doors.
Solution Approach 2:
The invention adds a dimensional aspect to the fastening system by incorporating horizontally extending support wings that distribute loads laterally across the upright. This dimensional expansion from a single-point screw connection to a distributed surface contact system enhances the ability to support heavy doors in the open position by spreading forces across a larger area.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The device consists of a flattened metal profile (5), which can be fastened to the upright (2) or subframe of the door by means of screws (4') and which includes a T-shaped appendage (7) on the end thereof and face facing the frame (1) of the door which can fit into a narrowed slot (8) provided in the frame (1) of the door. Said profile additionally includes, in correspondence with one of the ends thereof, the end opposite the opening direction of the swing door (9), a wing (10) perpendicular to the main body, determining a self-levelling support element that laterally clasps the upright (2) or subframe, adapting thereto, ensuring the levelling of the assembly. The flattened metal profile (5) includes laterally to the T-shaped appendage (7) a bent wing (11) determining a support and fastening means by screwing a strip (12) of plasterboard to finish the internal edge of the wall at the level of the frame of the. This allows door assembly times to be significantly minimised.