Metal Door Corner Support Assembly Shear Block Design
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Solution Overview
Problem
Commercial metal framed doors face structural integrity issues due to shearing and torqueing forces, and existing corner support frameworks are bulky, cumbersome, and require notching for installation.
Innovation Solution
A corner support assembly with extruded vertical and horizontal frame members that secure with screws, welds, and threaded bolts, featuring shear blocks with multiple holes for plug welding and an elongated threaded bolt, allowing snap-fit attachment of door molding without notching, and a rubber glass setting block for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional corner joints are used to withstand shearing and torqueing forces, then structural integrity is improved, but the corner joint becomes bulky and cumbersome
Solution Approach 1:
The corner joint is divided into separate components: a corner bracket attached to the door frame and a separate reinforcement member that fits into a recess. This segmentation allows each component to be optimized independently, reducing overall bulk while maintaining strength through the distributed fastening system (screws, welds, and threaded bolts).
Solution Approach 2:
The reinforcement member is designed to nest within a recess in the door frame, with the corner bracket attached to the exterior surface. This nested configuration reduces the protruding dimensions of the corner joint while maintaining structural integrity through the embedded reinforcement and multi-point fastening system.
2Strength
If existing support frameworks are used, then some structural support is provided, but they require notching for installation which complicates the manufacturing process
Solution Approach 1:
The corner bracket and reinforcement member are pre-designed with integrated fastening features (pre-drilled holes, welded connections, threaded bolts) that eliminate the need for notching during installation. The reinforcement member fits into a pre-formed recess without requiring modification of the door frame, simplifying the manufacturing and installation process while maintaining structural support.
3Strength
If multiple fastening means are implemented, then structural integrity is improved, but the assembly process becomes more complex
Solution Approach 1:
Multiple fastening methods (screws, welds, and threaded bolts) are combined into a single integrated corner bracket and reinforcement member assembly. The corner bracket serves as a unified component that incorporates all fastening features, allowing the assembly process to be streamlined while maintaining the benefits of multiple fastening means for enhanced structural integrity.
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
Provides a dimensionally stable reinforcement that enhances structural integrity, prevents shearing, and simplifies installation by eliminating the need for notching, while ensuring secure fastening and protection for glass panes.
Implementation Method 1
The shear block has multiple holes that allow solder to be poured into the dedicated holes for a plug weld to fasten the shear blocks to the horizontal frame members
Implementation Method 2
An elongated threaded bolt reinforces the connection between the horizontal and vertical frame members
Implementation Method 3
A rubber glass setting block is applied on the inside of frame members for full glass edge protection
Data Source
AI summary
A corner support assembly for metal framed doors reinforces mounting of a metal door, so that the door molding easily attaches to extruded vertical and horizontal frame members of the corner support assembly. A top wall of the frame members with guide lines and molding that sits into a snap-fit mating relationship with corresponding frame members; thereby negating the need for notching. A heavy shear block provides structural integrity. The shear block abuts the intersection of the horizontal and vertical frame members, sliding between molding grooves in the vertical frame member. The shear block and horizontal and vertical frame members are secured into place with at least one of: a shear screw and a plug weld. An elongated threaded bolt reinforces connections between the horizontal and vertical frame members. A rubber glass setting block rests adjacent to the top wall of frame members to receive a glass pane.