Door Hinge Mounting on Hollow Profiles
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Solution Overview
Problem
The attachment of door hinges to hollow profiles in door frames and door leaves is challenging due to the inability to distribute weight and leverage forces effectively, leading to material stress and potential failure, and existing solutions complicate assembly and increase the risk of material damage.
Innovation Solution
A door arrangement where the door hinge rests on an outer surface of the hollow profile with a base body inserted into an opening, featuring adjustable clamping hooks that provide a positive and/or non-positive connection, allowing for even load distribution and easy assembly, with reinforced inner webs and optional cutting edges for enhanced support and guidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If door hinges are screwed directly to hollow profiles, then assembly is simple, but point loads cause high material stress and risk of material failure
Solution Approach 1:
A solid mounting block is introduced as an intermediary component between the door hinge and the hollow profile. The mounting block receives point loads from the hinge screws and distributes them over a larger area of the hollow profile through its back surface, reducing material stress while maintaining simple assembly through screw connections.
Solution Approach 2:
The hollow profile is locally reinforced by inserting solid mounting blocks at specific locations where door hinges are mounted. This creates localized areas of high strength and stiffness exactly where loads are applied, while the rest of the hollow profile maintains its lightweight characteristics.
2Strength
If recesses are milled into hollow profiles for door hinge embedding, then large-area support is achieved, but assembly complexity increases and material is removed
Solution Approach 1:
Solid mounting blocks are pre-formed with recesses or mounting surfaces ready for door hinge attachment before being inserted into the hollow profile. This eliminates the need to mill recesses into the hollow profile during assembly, reducing assembly complexity while still providing large-area support for load distribution.
3Reliability
If solid door frames and door leaves are used with milled recesses, then door hinge attachment is reliable, but weight increases and manufacturing complexity increases
Solution Approach 1:
Instead of making the entire door frame or leaf solid to ensure reliable hinge attachment, solid mounting blocks are inserted only at the specific locations where door hinges are mounted. This provides reliable attachment points while the rest of the structure remains hollow and lightweight.
4Strength
If counterparts are inserted into hollow profiles for screwing, then material stress is reduced, but assembly becomes considerably more difficult
Solution Approach 1:
Solid mounting blocks serve as intermediary components that provide ready-made screw mounting surfaces. Door hinges can be screwed directly to these blocks using standard screw connections, maintaining ease of assembly while the blocks themselves distribute loads over larger areas of the hollow profile, reducing material stress.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A door assembly comprising a door frame, a hinge (3), and a door leaf pivotally connected to the door frame by the hinge (3). The door frame and/or door leaf has a hollow profile (1, 2) on one hinge side. The hinge (3) rests with a contact surface (9a, 9b) against an outer surface (10a, 10b) of the hollow profile (1, 2) and is inserted into an opening of the hollow profile (1, 2) by means of a base body (6a, 6b). The hinge (3) has a fastening device (12) which is supported by at least one adjustable clamping hook (13) on an inner surface of the hollow profile (1, 2). The invention also relates to a hinge (3) for such a door assembly.