Flush Hinge Fixing for Heavy Metal Doors
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Solution Overview
Problem
Conventional hinge fixing systems for heavy doors, such as fire and burglar-proof doors, are inadequate due to leverage effects and require adjustable solutions to withstand high usage frequencies and accidental stresses, while maintaining acoustic, thermal, and smoke transmission requirements.
Innovation Solution
A flush door system with at least two hinges, each comprising a central cylindrical lug on the door leaf side and two lugs on the frame side, connected by an axis, allowing for oblique fixation within the door frame's tubes, with anti-friction rings and adjustable threads for precise alignment and stress distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hinge fixing systems are used on heavy doors, then the door can be installed with standard hardware, but the system fails to withstand high usage frequencies and accidental stresses due to leverage effects
Solution Approach 1:
The hinge is divided into multiple independent parts: a first part fixed to the door leaf, a second part fixed to the frame, and a connecting axis. This segmentation allows each part to be optimized for its specific function and distributed the mechanical stresses across multiple connection points, improving overall reliability under high usage and accidental loads.
Solution Approach 2:
The hinge components are positioned in three-dimensional space with specific spatial relationships. The axis connects the two parts at an angle, and the components extend in multiple directions to distribute leverage effects. This 3D arrangement transforms the stress distribution from a single-plane problem to a multi-dimensional solution, enhancing mechanical resistance.
2Object-affected harmful factors
If flush door system is used with hinges in the same plane as the frame, then acoustic and fire safety requirements are maintained, but conventional fixing methods are inadequate for heavy doors
Solution Approach 1:
The hinge system is segmented into multiple parts that can be independently positioned and fixed. This allows the hinge mechanism to remain within the flush plane (maintaining acoustic and fire safety) while distributing the load-bearing functions across multiple components fixed at different locations, making it suitable for heavy doors.
Solution Approach 2:
The connecting axis acts as an intermediary element between the door leaf part and the frame part. It transfers and distributes the mechanical stresses from the heavy door while allowing both hinge parts to remain positioned within the flush plane, thus maintaining acoustic and fire safety requirements.
3Ease of manufacture
If hinge thickness is placed on the outside of the door leaf on the jamb side, then the hinge can be fixed on the edge of the door leaf, but it creates space incompatible with acoustic attenuation and flame transmission requirements
Solution Approach 1:
Instead of placing the hinge thickness in the horizontal dimension (protruding from the door edge), the hinge components are arranged in the vertical and depth dimensions. The first part is fixed to the door leaf face, the second part to the frame, and they connect via an axis, keeping all components within the flush plane and maintaining acoustic and fire safety.
Solution Approach 2:
Rather than having the hinge protrude outward from the door leaf edge (conventional approach), the hinge components are inverted to be fixed within the plane of the door and frame. The connection is achieved through internal fixing mechanisms and a connecting axis, reversing the traditional outward-protruding configuration.
Data Source
Figure 1~3
AI summary
The invention relates to a door panel and to a door panel and frame set, including at least two lift-off hinges in at least three parts connected by an axle, according to the so-called flush system, one surface of which is in the same plane as the door panel, in particular a metal door panel for attachment to a frame, the lift-off hinge including at least one attachment pin on the door panel side and at least two attachment pins on the frame side. The at least one pin of the lift-off hinge on the door panel side is a cylindrical pin having an outside thread which is screwed into a socket running diagonally through at least the hinge side corner of a tube within said door panel, to which said socket is attached. The at least two pins of the lift-off hinge on the frame side are capable of being attached by screwing to the inside of the frame by sockets or blocks welded or secured behind the frame.