Composite Door Frame with Wood Core and Plastic Shell

Solution Overview

Problem

Conventional door frame materials, particularly wood, are prone to decay and structural integrity issues due to environmental exposure, and alternative materials like all-plastic frames lack rigidity and resistance to impact damage.

Innovation Solution

A door assembly featuring a composite frame member with a core made of non-metallic material, preferably wood, and a two-piece top piece formed from a cellulosic-plastic composite, which includes wood fiber and thermoplastic, providing structural stability and decay resistance while allowing for hollow cavities and modular integration of accessories.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional wood frame materials are used, then a traditional wood appearance is achieved, but the frame is prone to decay and structural integrity issues due to environmental exposure

Engineering Contradiction:

Improvedecay resistanceVSAvoidenvironmental degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The frame member uses a composite construction with a wood core surrounded by an extruded plastic material layer. This composite structure combines the aesthetic benefits of wood with the decay resistance of plastic, protecting the wood core from environmental degradation while maintaining a traditional wood appearance.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The extruded plastic material acts as an intermediary protective layer between the wood core and the external environment. This plastic coating prevents moisture and harmful environmental factors from directly contacting the wood, thereby preventing decay while allowing the wood grain appearance to show through.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If all-plastic frames are used, then resistance to environmental degradation is improved, but structural strength and rigidity are reduced

Engineering Contradiction:

Improveenvironmental resistanceVSAvoidstructural strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The frame member uses a composite construction with a wood core surrounded by an extruded plastic material layer. This composite structure combines the aesthetic benefits of wood with the decay resistance of plastic, protecting the wood core from environmental degradation while maintaining a traditional wood appearance.

Inventive Principle:

Principle #40Composite materials

3Reliability

If vinyl cladded wood frames are used, then decay resistance is improved, but resistance to impact damage is reduced

Engineering Contradiction:

Improvedecay resistanceVSAvoidimpact damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The frame member uses a composite construction with a wood core surrounded by an extruded plastic material layer. This composite structure combines the aesthetic benefits of wood with the decay resistance of plastic, protecting the wood core from environmental degradation while maintaining a traditional wood appearance.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12037840B2Door assembly

Publication Date: 2024.07.16 ENDURA PRODS INC

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 including a storage compartment. 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.