Concealed Door Operator Nesting
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Solution Overview
Problem
Conventional door operators require multiple tradesmen for installation and feature a visible return spring and motor, which compromises aesthetic appeal and increases installation costs.
Innovation Solution
A door operator assembly without a return spring, where the electrical components, including a motor, are concealed within the door, utilizing a controller and sensors to manage the door's movement between open and closed positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a return spring and motor are used to operate the door, then the door can be moved between open and closed positions, but the mechanical components become visible and compromise aesthetic appeal
Solution Approach 1:
The door operator assembly is nested within the door structure itself, with the motor and mechanical components concealed inside the door thickness. The arm extends from the operator to operate the door, while the housing contains all mechanical elements, making them invisible from the exterior view.
Solution Approach 2:
The solution moves the mechanical components from a visible external dimension to a concealed internal dimension by embedding the operator within the door's thickness. This relocates the mechanism from a prominent external position to a hidden internal space, resolving the aesthetic conflict.
2Ease of operation
If a large motor and return spring are used to overcome spring pressure, then the door can be operated, but a large box must be mounted over the door opening to house the components
Solution Approach 1:
The motor and return spring are nested within the door's internal volume rather than requiring an external mounting box. The operator fits within the door thickness, eliminating the need for a large external housing that would occupy significant wall space.
Solution Approach 2:
The solution transitions from a two-dimensional external mounting approach to a three-dimensional internal embedding approach. By utilizing the door's thickness dimension, the system accommodates all mechanical components within the door itself, eliminating external space requirements.
3Reliability
If multiple tradesmen are used for door installation with security items, then the door can be properly installed, but installation costs and human factors increase
Solution Approach 1:
The door operator assembly integrates multiple functions into a single unified unit. The motor, return spring, arm, and control electronics are combined into one pre-assembled operator that replaces multiple separate components, simplifying installation while maintaining security functionality.
Solution Approach 2:
The integrated door operator serves multiple functions simultaneously: it provides door actuation, includes concealed mounting, incorporates security features, and offers aesthetic concealment. This multi-functional design reduces the need for multiple specialized tradesmen by consolidating installation requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the number of tradesmen required for installation, enhances aesthetic appeal by hiding the mechanical components, and provides a more efficient and cost-effective door operation system.
Implementation Method 1
A door operator includes a first door skin, a second door skin spaced apart from the first door skin and a door operator disposed between the first door skin and the second door skin
Implementation Method 2
A current sensor generates a current signal corresponding to the current to the motor
Implementation Method 3
A position sensor in communication with the door arm generates a position signal corresponding to the position of the door relative to the frame
Data Source
AI summary
A door assembly includes a first door skin, a second door skin spaced apart from the first door skin and a door operator disposed between the first door skin and the second door skin. An arm extends from the door operator. The door operator includes a motor moving the arm to move the door between a closed position and an open position and between the open position and the closed position. A current sensor generates a current signal corresponding to the current to the motor. A position sensor in communication with the door arm generates a position signal corresponding to the position of the door relative to the frame. A controller communicates with the sensor and the motor. The controller controls a motor current to the motor in response to the current signal and the position signal.