Door Hardware Installation Using Segmented Drill Recesses
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Solution Overview
Problem
The installation of conventional door hardware, such as latch and strike assemblies, is time-consuming and difficult, especially when working with wooden doors and jamb, as it requires cutting rebates which can be messy and requires specialized tools like routers and templates, which are often not readily available on-site.
Innovation Solution
A method involving drilling parallel bores with specific spacings and depths to create a recess in the door or jamb, allowing for the installation of a receiving member with a base plate, wall, and flange, which engages cusps and hides the recess, eliminating the need for chiseling or routing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional latch and strike assemblies are installed using traditional rebate cutting methods, then the hardware can be properly installed, but the installation process becomes time-consuming and requires specialized tools like routers and templates
Solution Approach 1:
The rebate cutting process is segmented into multiple sequential drill holes rather than requiring a single continuous routing operation. This segmentation allows the use of basic drill tools instead of specialized routing equipment, simplifying the installation process and reducing the need for expensive tools while maintaining proper rebate formation for latch and strike assemblies
Solution Approach 2:
The template is used to pre-mark the exact positions and patterns of drill holes before installation begins. This preliminary action ensures accurate rebate formation without requiring the installer to manually measure and mark during the installation process, thereby reducing installation time and eliminating the need for complex routing operations
2Ease of manufacture
If rebates are cut using basic hand tools and chisels, then installation can proceed with simple tools, but the process is time-consuming and leaves an untidy appearance around the edges
Solution Approach 1:
Instead of attempting to cut a smooth continuous rebate with chisels, the process segments the rebate formation into multiple discrete drill holes. This segmentation allows each hole to be precisely positioned and sized, creating a clean, uniform pattern that provides a tidy appearance while being achievable with basic hand drill tools
Solution Approach 2:
The template guides the drilling of holes that extend slightly beyond the exact rebate boundaries. This excessive action ensures complete removal of material where needed, and the resulting pattern of holes provides a clean, defined edge that looks tidy rather than crude, while still being achievable with simple tools
3Shape
If curved-end receiving members are used to match curved rebate profiles, then the installation accommodates aesthetic requirements, but specialized tools like routers and template jigs are required which are expensive and difficult to transport
Solution Approach 1:
Instead of cutting the rebate to match the curved shape of the receiving member (which would require complex routing), the invention inverts the approach by using a template with curved drill hole patterns that naturally create a recess accommodating the receiving member. This inversion allows the use of simple drill tools rather than complex routers, reducing device complexity while achieving the same aesthetic result
Solution Approach 2:
The template itself is a simplified copy or representation of the final rebate profile, encoded in the pattern of curved drill hole arrangements. By following this template, the installer reproduces the correct recess shape without needing to physically route the complex curved profile, thereby eliminating the need for expensive template jigs and routing equipment
Data Source
AI summary
A method of installing a receiving member for a latch assembly or strike assembly in a door or jamb. The receiving member including a base plate, a wall around the perimeter of the base plate, the wall extending substantially perpendicular to the base plate, and a flange extending outwardly from the perimeter of the wall distal the base plate. The base plate has an aperture therein configured to allow a latch to pass therethrough.