Carved Solid Face Door with CNC Milling Window

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Solution Overview

Problem

Existing door manufacturing methods, such as stamped metal and multiple-piece construction, face challenges in design flexibility, cost-effectiveness, and quality control, particularly for large or intricate designs, due to tooling limitations and time-consuming assembly processes.

Innovation Solution

The use of computer-aided machinery, like CNC milling, to carve designs directly into a solid base material, allowing for efficient and flexible creation of door designs that emulate traditional construction methods, including frames, mullions, and raised panels, with the option of a backing for structural support and precise alignment of overlays.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If stamped metal or vinyl exterior is used, then manufacturing cost is reduced, but design flexibility is limited due to tooling requirements

Engineering Contradiction:

Improvemanufacturing costVSAvoiddesign flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent uses computer-aided machinery to carve designs directly into a solid base material, creating a copy of the desired design pattern without requiring expensive stamping tooling. This allows for high design flexibility while maintaining cost-effectiveness by eliminating the need for specialized stamping equipment and molds.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces traditional mechanical stamping processes with computer-aided carving machinery. This substitution eliminates the need for expensive stamping tools and allows for greater design flexibility through digital programming, while maintaining manufacturing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If multiple-piece construction is used, then design flexibility is improved, but manufacturing time and assembly complexity increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent merges multiple construction pieces into a single solid base material that is then carved to emulate the appearance of multiple-piece construction. This eliminates the need for separate fabrication and assembly steps, significantly reducing manufacturing time while maintaining design flexibility through the carving process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent segments the design into carved elements (frames, mullions, raised panels) that are created through computer-aided machining of a solid base. This segmentation allows for complex designs to be achieved through a single integrated manufacturing process rather than assembling multiple separate components.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If multiple-piece construction is used, then design complexity is improved, but quality control issues increase due to alignment difficulties

Engineering Contradiction:

Improvedesign complexityVSAvoidalignment precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent combines multiple design elements into a single solid base material that is carved as one integrated piece. This eliminates alignment issues between separate components and ensures consistent quality control, while still achieving complex designs through the carving process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses computer-aided machinery to precisely copy the desired design pattern directly into the solid base material. This digital copying process ensures high manufacturing precision and eliminates the alignment errors that occur when assembling multiple separate pieces.

Inventive Principle:

Principle #26Copying

4Productivity

If traditional stamping methods are used, then production speed is maintained, but tooling cost becomes expensive for multiple designs

Engineering Contradiction:

Improveproduction speedVSAvoidtooling cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent uses computer-aided machinery to create designs by carving a solid base material, eliminating the need for expensive stamping tooling. This approach maintains production speed while significantly reducing tooling costs, allowing for multiple designs to be produced without requiring new tooling for each design variant.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces expensive mechanical stamping tooling with computer-aided carving machinery. This substitution maintains manufacturing efficiency and production speed while eliminating the high tooling costs associated with traditional stamping methods, enabling cost-effective production of multiple designs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8646233B2Carved solid face door having a window formed therein and methods of fabrication

Publication Date: 2014.02.11 FIMBEL III EDWARD

AI summary

Embodiments of a carved solid face door having a window formed therein and methods of fabrication are disclosed herein. In some embodiments, a carved solid face door may include a solid base having a face and an opposing rear surface; and a window carved into the face and having an opening passing through the face to the opposing rear surface, wherein the window includes at least one of a frame, a trim, a molding, or mullions carved into the face that emulate the appearance of multiple-piece construction.