Door Leaf Lock Pocket Floating Mounting for Planarity
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Solution Overview
Problem
Existing door manufacturing methods face challenges in achieving desired planarity due to heat-induced distortions during welding and firm connections that can lead to optical impairments in door leaves with lock pockets.
Innovation Solution
A door leaf design featuring a sleeve-shaped or box-shaped lock pocket made of sheet metal that is loosely accommodated in the door leaf body, connected via a heat-free cold connection, such as a clip connection, allowing for floating mounting and adjustment during assembly, ensuring the lock pocket is fixed only when the mortise lock is screwed in.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the lock pocket is welded to the lock reinforcement, then the connection strength is improved, but thermal distortion occurs and planarity deteriorates
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical fastening system consisting of fastening elements (screws, clips, or rivets) that mechanically connect the lock pocket to the lock reinforcement without generating heat, thereby eliminating thermal distortion while maintaining connection strength
Solution Approach 2:
The patent introduces fastening elements as an intermediary component between the lock pocket and lock reinforcement, serving as a mediator that provides secure mechanical connection without direct thermal contact, thus preventing heat-induced planarity degradation
2Stability of the object's composition
If the lock pocket is firmly connected to the door leaf body, then the structural stability is improved, but optical quality deteriorates due to heat-induced distortions
Solution Approach 1:
The patent substitutes thermal welding with mechanical fastening methods that provide sufficient structural stability for firmly connecting the lock pocket to the door leaf body while avoiding the harmful thermal effects that compromise optical quality
Solution Approach 2:
The patent converts the potential harm of thermal distortion into a benefit by deliberately choosing a cold connection method, where the absence of heat input becomes the advantageous factor that preserves the optical quality of the door leaf while still achieving firm structural connection
3Productivity
If welding is used to attach the lock pocket, then the manufacturing speed is improved, but thermal distortion increases and planarity deteriorates
Solution Approach 1:
The patent replaces the welding process with mechanical fastening operations that can be performed quickly and efficiently, maintaining high manufacturing speed while eliminating the thermal distortion that degrades planarity
Solution Approach 2:
The patent employs simple, easily replaceable fastening elements that can be quickly installed and removed if necessary, enabling efficient manufacturing cycles without the need for complex welding procedures, thus maintaining productivity while ensuring planarity
Data Source
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AI summary
In order to produce a door leaf in large series cost-effectively with a high-quality optical appearance and, in particular, great flatness, the invention provides a door leaf (10) with a sleeve- or box-shaped lock pocket (52) made of a flat material or sheet material (62) for receiving a mortise lock (56), wherein the lock pocket (52) is received loosely in a door leaf body in such a way that it is movable with play, at least in the thickness direction, before the mortise lock (56) is attached, and can be fixed by attaching the mortise lock (56).