Foldable Cardboard Door Protector with Hardware Cutouts
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Solution Overview
Problem
Existing door protective solutions are either not disposable, inconvenient to store, or only protect one side of a door, failing to provide adequate impact protection and allowing door usage while covered.
Innovation Solution
Inexpensive, foldable door protective covers made of corrugated cardboard or paper fiberboard with non-abrasive coatings and EPE foam, allowing full door functionality and protection of both sides, featuring perforations and die cuts for door hardware access and adjustable sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a door protective cover is made reusable with padding and Velcro material, then impact protection and durability are improved, but cost of production increases and storage convenience deteriorates
Solution Approach 1:
The patent applies disposable cardboard covers that provide adequate impact protection for construction environments without requiring reuse. The cardboard material is selected and designed to be sufficiently protective for the intended temporary use period, eliminating the need for expensive reusable materials while maintaining protection effectiveness.
Solution Approach 2:
The patent uses composite construction combining cardboard with foam padding layers to achieve impact protection comparable to more expensive reusable materials. The multi-layer composite structure provides cushioning and protection while keeping material costs low and the product disposable.
2Strength
If a door protective cover covers substantially the entirety of the door, then impact protection is improved, but door functionality deteriorates due to handle coverage
Solution Approach 1:
The patent removes or creates openings in the protective cover at the handle location, extracting the portion that would interfere with door operation. This allows the cover to provide comprehensive protection while maintaining full access to door handles and hardware.
Solution Approach 2:
The protective cover is designed with varying properties across its surface - solid coverage for protection areas and openings or cutouts for operational areas. This local differentiation ensures maximum protection where needed while preserving door functionality where handles and hardware are located.
3Strength
If a door protective cover is made thick and rigid for proper operation and protection, then impact protection is improved, but foldability for storage deteriorates
Solution Approach 1:
The protective cover is divided into multiple segments or panels connected by fold lines, allowing the rigid structure to be collapsed into a compact form for storage. The segmented design maintains structural integrity for protection while enabling easy folding and portability.
Solution Approach 2:
The protective cover incorporates flexible elements or fold lines that allow it to transition between rigid (when installed for protection) and flexible (when folded for storage). This dynamic behavior enables the cover to provide rigid protection during use while being easily stowed when not in use.
4Duration of action of stationary object
If a door protective cover is made as a single reusable unit, then durability is improved, but storage efficiency deteriorates due to size and weight
Solution Approach 1:
The patent employs disposable protective covers that eliminate storage concerns entirely. Each cover is used once or for a limited duration during construction projects, then discarded, removing the need for long-term storage infrastructure and management of reusable covers.
Solution Approach 2:
The protective cover is designed to fold into a compact nested configuration that minimizes storage volume. Multiple covers can be nested within each other or stacked efficiently, maximizing storage efficiency even for reusable variants.
Data Source
AI summary
Embodiments of door protectors are described. One typical embodiment comprises front and rear corrugated cardboard panels that are draped over a door by way of one or more pieces of saddle tape that join the panels along their respective top edges. A plurality of folds, perforations and cutouts are provided on the faces of the panels to permit access to the door's hardware. Accordingly, the door can be operated in a traditional manner while providing impact and damage protection to the door. The panels include a plurality of widthwise folds that permit the door protector to be folded for transport and storage. In variations, the edge straps are provided often comprised of hook and loop material to both secure the protector in a folded configuration and to an associated door.