Reusable Door Liner Alignment Tool for Uniform Gap Installation
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Solution Overview
Problem
Existing door sets require single-use alignment brackets that are difficult to mount and result in material waste, protrusion from the door liner, and increased installation complexity and cost, due to their integration within the door liner.
Innovation Solution
A door alignment tool with prongs and a base plate that can be removably secured to the door liner or wall, allowing precise alignment and reusability, eliminating the need for protruding brackets and enabling standard architrave installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If alignment brackets are integrated within the door liner, then alignment function is provided, but material waste increases and installation complexity increases
Solution Approach 1:
The alignment tool is divided into separate components: a reusable door liner, a removable alignment bracket, and mounting hardware. This segmentation allows the alignment bracket to be removed and reused across multiple door installations, eliminating material waste while maintaining the alignment function.
Solution Approach 2:
The alignment bracket is designed to be temporary and removable rather than permanent. After serving its alignment purpose during installation, the bracket can be removed and recovered for use in subsequent door installations, preventing material waste.
2Manufacturing precision
If alignment brackets are mounted within the door liner, then alignment is achieved, but mounting difficulty increases
Solution Approach 1:
The door liner is pre-equipped with recesses and counterbores during manufacturing to accommodate the alignment bracket. This preliminary preparation simplifies the installation process, as the bracket can be directly mounted into the pre-formed recesses without complex field modifications, while still achieving precise alignment.
3Reliability
If alignment brackets protrude from the door liner, then alignment is maintained, but architrave installation complexity increases
Solution Approach 1:
The alignment bracket is extracted from the permanent structure and made removable. After alignment is achieved, the bracket can be removed before architrave installation, eliminating the need for complex recesses in the architrave and simplifying the overall installation process while maintaining alignment stability during the critical alignment phase.
4Manufacturing precision
If multiple alignment brackets are used per door set, then alignment accuracy improves, but installation time increases
Solution Approach 1:
The alignment bracket is designed as a universal component that can be reused across multiple door installations. This multi-functionality allows a single bracket to serve multiple purposes and multiple door sets, reducing the total number of brackets needed and thereby increasing installation productivity without compromising alignment accuracy.
Data Source
AI summary
A door set for installation in a doorway in a wall. The door set comprises a door liner arranged to be mounted by its outer edges to the wall adjacent the doorway, and further arranged to have a door movably mounted to an inner edge; and at least one door alignment tool, comprising a base plate, at least one prong extending from a face of the base plate, and at least one alignment fixing on the base plate. The at least one prong is arranged to be inserted into a corresponding at least one bore in one of the door liner and the wall. The door alignment tool is arranged to be removably and adjustably secured to the other of the door liner and the wall adjacent the doorway using the alignment fixing.