Composite Door Frame with Wood Core and Plastic Coating
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Solution Overview
Problem
Conventional door frame materials, particularly wood, are prone to decay and structural integrity issues due to environmental exposure, and existing alternatives like all-plastic frames lack strength and rigidity, while attempting to address these issues often interfere with hardware fasteners or compromise appearance.
Innovation Solution
A door assembly featuring a composite frame member with a core made of non-metallic material, preferably wood, combined with a cellulosic-plastic composite top piece that includes hollow cavities and a weather strip slot, providing structural stability and decay resistance while allowing for easy installation and hardware compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wood frames are used, then appearance and structural strength are improved, but decay resistance and moisture resistance deteriorate
Solution Approach 1:
The frame member uses a composite construction with a wood core providing structural strength and a plastic coating layer providing decay and moisture resistance. This composite structure allows the frame to simultaneously achieve the aesthetic and structural benefits of wood while gaining the durability and weather resistance of plastic materials.
2Reliability
If aluminum cladded wood frames are used, then decay resistance is improved, but cost increases
Solution Approach 1:
The invention uses a plastic-coated wood frame that provides decay resistance at a lower cost than aluminum cladded alternatives. The plastic coating applied to the wood core offers comparable protective properties to aluminum cladding but at reduced material and manufacturing costs.
3Reliability
If vinyl cladded wood frames are used, then decay resistance is improved, but impact resistance deteriorates
Solution Approach 1:
The frame member combines a rigid wood core that provides structural strength and impact resistance with a plastic coating that provides decay resistance. The wood core's inherent rigidity compensates for the softer plastic coating, maintaining overall impact resistance while achieving decay protection.
4Reliability
If all-plastic extruded frames are used, then decay resistance is improved, but rigidity and structural strength deteriorate
Solution Approach 1:
The invention uses a wood core that provides the necessary rigidity and structural strength, covered by a plastic layer that provides decay resistance. This composite structure overcomes the limitations of all-plastic frames by using the wood's natural rigidity while protecting it from decay through the plastic coating.
5Strength
If stiffening components are added to all-plastic frames, then structural strength is improved, but hardware fastener compatibility deteriorates
Solution Approach 1:
The wood core in the composite frame member provides inherent structural strength without requiring additional stiffening components. The plastic coating maintains a smooth surface that is compatible with hardware fasteners, allowing for easy installation and attachment of door components without the interference problems associated with extruded stiffening elements.
Data Source
AI summary
A door assembly and a frame member for a door assembly. The door assembly may include at least one door panel and a door frame having a plurality of frame members including a header and a pair of side jambs. The invention may also be considered a frame member. The frame member may include a core; and a top piece adjoining the core to form a structural member. The core and the top piece may be a composite of cellulosic material and at least one other material. The top piece may be a two-piece top piece and may include hollow cavities. Also disclosed are door jamb frame members and mullion frame members.