Universal Door Slab With Predrilled Lock Alignment
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Solution Overview
Problem
Existing doors face challenges in compatibility with multiple door frame configurations, requiring time-consuming and error-prone on-site drilling for lock bolt hole alignment, especially when multiple manufacturers are involved, leading to inefficiencies and potential loss in productivity.
Innovation Solution
A universal door slab with predrilled lock bolt holes compatible with different manufacturers' frame configurations, utilizing a lock plate and trim plates to align with specific frame bolt holes, facilitating easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If on-site drilling is performed to align lock bolt holes with frame bolt holes, then compatibility with specific frame configurations is achieved, but installation time increases and human error risk increases
Solution Approach 1:
The door slab is predrilled with multiple lock bolt holes at different locations during manufacturing, and includes a lock plate with multiple pre-positioned holes and trim plates with various configurations. This preliminary preparation eliminates the need for on-site drilling, allowing installers to simply select and assemble the appropriate pre-configured components for different frame types, thereby reducing installation time while maintaining compatibility.
Solution Approach 2:
The door slab incorporates multiple lock bolt holes and a lock plate with multiple holes that can accommodate different frame configurations (e.g., CECO, Curries, Steel Craft, Pioneer). This universal design allows a single door slab to fit multiple manufacturers' frames without requiring custom drilling, achieving both adaptability and time efficiency.
2Adaptability or versatility
If on-site drilling is performed to align lock bolt holes with frame bolt holes, then compatibility with specific frame configurations is achieved, but accuracy decreases due to human error
Solution Approach 1:
The lock bolt holes are predrilled and prepositioned during manufacturing with precise alignment to the lock plate holes and trim plate configurations. This eliminates on-site drilling and the associated human error, ensuring accurate alignment between the door slab components and various frame configurations.
Solution Approach 2:
The lock plate and trim plates serve as intermediary components that bridge the door slab and the frame. These intermediaries have pre-positioned holes that align with both the door slab's lock bolt holes and the frame's bolt holes, ensuring accurate alignment without requiring direct drilling into the door slab on-site.
3Adaptability or versatility
If multiple door types are used for different manufacturers, then compatibility with specific frames is ensured, but device complexity and inventory requirements increase
Solution Approach 1:
A single universal door slab design incorporates multiple lock bolt holes and works with a lock plate that has multiple hole configurations. This allows one door slab type to serve multiple manufacturers (CECO, Curries, Steel Craft, Pioneer), eliminating the need to stock and install different door types for different frames, thereby reducing complexity and inventory requirements.
Solution Approach 2:
The door system is segmented into modular components: the door slab with multiple lock bolt holes, the lock plate with multiple holes, and various trim plate configurations. This segmentation allows flexible assembly where the same door slab can be paired with different lock plate and trim plate combinations to suit different manufacturers, simplifying inventory while maintaining compatibility.
Data Source
AI summary
A door assembly comprises a door panel with a plurality of lock bolt holes extending through an edge of the door panel; a lock plate with a plurality of lock plate holes, wherein the lock plate is coupled to the edge of the panel and each of the plurality of lock plate holes is aligned with a respective lock bolt hole of the plurality of lock bolt holes; and a removable trim plate coupled to the lock plate and disposed over the plurality of lock plate holes.