Preassembled Door System with Anti-Sag Hinges and Concealed Fasteners
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Solution Overview
Problem
Conventional door and window installation systems are time-consuming, require multiple tools, and often result in misalignment and sagging issues, especially in residential secondary door installations, which can lead to operational and aesthetic problems.
Innovation Solution
A preassembled door system with integrated fasteners, anti-sag hinges, and concealed fastener covers that can be installed quickly with minimal tools, featuring a frame with preloaded screws and adjustable components to ensure proper alignment and prevent sagging, allowing for rapid installation and improved aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional door and window installation systems are used, then the installation process is thorough and secure, but the installation time is excessive and multiple tools are required
Solution Approach 1:
The fasteners are pre-loaded into the frame members during manufacturing, and the frame is pre-assembled with all components in place before delivery to the installation site. This preliminary preparation eliminates the need for on-site fastener installation and component assembly, enabling rapid installation in under ten minutes with minimal tools
Solution Approach 2:
The building system is divided into modular components (frame members with integrated fastener-receiving portions, separate fasteners, and panel sections) that can be independently manufactured and then quickly assembled. This segmentation allows for pre-manufacturing preparation while maintaining installation flexibility
2Manufacturing precision
If conventional installation methods are used, then proper alignment can be achieved, but misalignment and sagging issues frequently occur
Solution Approach 1:
The hinge assembly incorporates an adjustable panel hinge portion that can be positioned at different locations and orientations. This adjustability allows installers to compensate for minor variations in opening dimensions and prevent panel sagging by optimizing the hinge geometry during installation
Solution Approach 2:
The system includes self-aligning features where the pre-loaded fasteners and integrated receiving portions guide proper alignment during installation. The components are designed to work together to automatically establish correct positioning without requiring complex alignment procedures or specialized tools
3Strength
If exposed fasteners are used for installation, then secure attachment is achieved, but aesthetic appearance is compromised
Solution Approach 1:
The fastener cover is designed to concealing the exposed fastener head while leaving the fastener shaft exposed for attachment. The cover is attached to the panel and positioned to hide the unsightly fastener head, maintaining both secure attachment and aesthetic appearance
Data Source
AI summary
Building systems including a frame with a horizontal member from which first and second vertical bars downwardly extend and a panel attached to the frame. The building systems include at least one of an integrated fastener cover that is moveable to a closed position that covers a portion of a fastener, a gusset assembly with a junction cover positioned at a corner junction between two adjacent portions of a panel, and hinge assemblies that reduce the sagging of a panel, such as a door.