Extruded Composite Door Hardware Supports From Wood Waste
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Solution Overview
Problem
Manufacturing door hardware supports from solid or laminated wood results in material waste and requires additional materials, increasing production costs and environmental impact.
Innovation Solution
A method of manufacturing door hardware supports using a moldable wood composite formed from wood particulate waste, combined with a thermoplastic polymer, which is extruded and scored to create a composite board that can be manually broken into individual supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If door hardware supports are manufactured using solid or laminated wood, then the supports provide structural support, but material waste increases and production costs rise
Solution Approach 1:
The patent changes the physical state of wood from solid/laminated form to wood particulate (chips, sawdust, fibers), then transforms it into a molded composite material. This parameter change enables the utilization of waste wood particles while maintaining structural integrity through the composite formulation and molding process.
Solution Approach 2:
The patent creates a composite material by combining wood particulate with binding agents and other materials to form a molded door hardware support. This composite approach allows the use of waste wood particles as the primary structural material, reducing material waste while providing the necessary strength for door hardware support.
2Strength
If door hardware supports are manufactured using solid or laminated wood, then the supports provide structural support, but production costs increase
Solution Approach 1:
The patent changes the form of wood from expensive solid or laminated material to low-cost wood particulate waste, then processes it through molding to create the support. This parameter change significantly reduces material costs while maintaining the structural support function.
Solution Approach 2:
The patent recovers and reuses wood particulate waste generated during door manufacturing as the primary material for door hardware supports. This recovery process eliminates the need to purchase additional wood materials, thereby reducing production costs while providing structural support.
3Loss of substance
If wood particulate waste is used to create door hardware supports, then material waste is reduced, but the supports must be manually broken into individual pieces
Solution Approach 1:
The patent designs the molded wood composite support with predetermined break lines that segment the continuous mold into multiple individual door hardware supports. This segmentation allows the entire molded piece to be easily separated into discrete units by manual breaking at the predetermined lines, eliminating the need for complex cutting or machining operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces material waste and production costs by utilizing wood particulate waste to create structurally rigid door hardware supports, enhancing the stability and strength of hollow or semi-solid core doors.
Implementation Method 1
forming a moldable wood composite using the collected wood particulate
Implementation Method 2
passing the moldable wood composite through a die including a rectangular cross-section to form a wood composite extrusion
Data Source
AI summary
This disclosure is directed to composite door hardware supports and methods of manufacturing the same. The composite door hardware supports can be formed using a wood particulate. The wood particulate can include a waste product of manufacturing one or more doors. In some cases, the composite door hardware supports can be formed by combining wood particulate with a polymer to form a moldable wood composite and passing the moldable wood composite through a die to form a wood composite extrusion. In some cases, the composite door hardware supports can be formed by scoring the wood composite extrusion at one or more breakage lines. The wood composite extrusion can then be broken at the one or more breakage lines to form the composite door hardware supports.