Sliding Barn Door Hardware with Height Extension
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Solution Overview
Problem
Existing sliding door systems, particularly barn-style doors, require new door slabs when upgrading from hinged doors, as the hinged door slabs are typically too small, and there is a need for an easy-to-install and aesthetically appealing solution that can extend the door slab size.
Innovation Solution
A sliding barn door system that includes a door slab with top and bottom extensions, featuring H-shaped profiles with flanges and attachment members, allowing the door slab to be extended in height by securing these extensions to the existing door slab, enabling the door to reach from the floor to a top rail, with low-friction contact members for smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a hinged door slab is used for a barn-style sliding door, then the door slab size is insufficient to cover the wall area, but replacing with a new larger door slab increases material cost and waste
Solution Approach 1:
The door assembly is segmented into the existing door slab and separate extension members that can be attached to increase the overall height. This allows the original door slab to be retained and reused while adding only the necessary extension material, rather than discarding the original slab and purchasing a completely new larger door.
Solution Approach 2:
Instead of discarding the existing hinged door slab when converting to a barn-style sliding door, the invention recovers and reuses it by attaching extension members to increase its height. This prevents material waste and reduces the need for new door slab production.
2Area of stationary object
If extension members are added to increase door slab height, then the door can cover the wall area, but the device complexity increases
Solution Approach 1:
The extension members are designed as separate, modular components that can be independently manufactured and attached to the door slab. This segmentation simplifies the overall system by allowing each component to be optimized separately and assembled through straightforward attachment mechanisms.
Solution Approach 2:
The extension members serve multiple functions: they increase the door height to cover the wall area, provide attachment points for the sliding hardware, and maintain the structural integrity of the door assembly. This multi-functionality reduces the need for additional separate components.
3Length of moving object
If the door slab height is increased to reach from floor to top rail, then the door can function as a barn-style sliding door, but the manufacturing complexity increases
Solution Approach 1:
Rather than manufacturing a single large door slab of the required height, the invention segments the door into the original smaller slab and separate extension members. This allows the original slab to be reused in its existing size while the extensions are manufactured separately and attached, simplifying the manufacturing process.
Solution Approach 2:
The extension members are designed to be pre-fabricated to specific lengths and then attached to the door slab. This preliminary preparation of components simplifies the final assembly process and allows for standardized manufacturing of extension pieces that can be used across multiple door conversions.
Data Source
AI summary
The present disclosure provides for a sliding (barn-style) door and methods and hardware for mounting. The sliding barn door includes a door slab and mounting hardware including a top extension and a bottom extension. The top and bottom extensions each have a rectangular face having substantially the same dimensions and configured to lengthen the height of the door slab.