Door Leaf Connecting Profile for Thermal Expansion Management
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Solution Overview
Problem
Conventional door leaves experience visible deformations and distortion due to temperature fluctuations, particularly when exposed to sunlight, as the thermally insensitive insulating materials between the panels do not participate in thermally induced movements, leading to mechanical stresses and bulges in the paneling.
Innovation Solution
A door leaf design featuring a panel-shaped structure with a connecting profile that extends beyond the insulating layer, incorporating mechanical connecting elements like pins, bolts, and screws, allowing for a flexible connection between the weather-side paneling and the door leaf frame, enabling relative movement to accommodate thermal expansions, and utilizing elastic stops and sealing elements to manage temperature-induced stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid insulating material is used between the panels, then thermal and acoustic insulation is improved, but the insulating layer causes warping and bulges in the panels due to temperature fluctuations
Solution Approach 1:
The insulating layer is segmented into multiple independent foam cores instead of being a single solid piece. This segmentation allows each foam core to independently accommodate thermal expansion and contraction of the panels without causing deformation, while still providing effective thermal and acoustic insulation.
Solution Approach 2:
The insulating material changes from a solid, rigid structure to a foamed, flexible structure with cellular geometry. This parameter change in material structure allows the insulation to maintain its thermal and acoustic properties while gaining the ability to flex and accommodate panel movements caused by temperature variations.
2Stability of the object's composition
If the panels are rigidly fixed to the door leaf frame, then structural stability is improved, but thermal expansion causes visible deformations and bulges
Solution Approach 1:
The connection between the panels and door leaf frame transitions from a rigid, static connection to a dynamic, flexible connection through the foam core. The foam allows the panels to move relative to the frame in response to thermal expansion while maintaining overall structural stability, preventing visible deformations.
3Length of moving object
If the insulating layer is made thin, then the door leaf thickness is reduced, but insulation effectiveness and stress absorption are compromised
Solution Approach 1:
The foam core acts as a flexible insulating film that provides effective thermal and acoustic insulation in a thin profile. The cellular structure of the foam allows it to maintain insulation performance while being thin enough to accommodate panel movements without requiring excessive thickness.
4Strength
If mechanical connecting elements are used to secure the panels, then structural strength is improved, but the connection creates stress points that lead to deformations under thermal load
Solution Approach 1:
The foam core serves as an intermediary between the panels and the mechanical connecting elements. It distributes the mechanical loads and thermal stresses uniformly across the panel surfaces, preventing stress concentration at connection points that would otherwise cause localized deformations and bulges.
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
The solution effectively reduces mechanical stresses and prevents visible deformations by allowing the weather-side paneling to float relative to the door leaf frame, absorbing thermal expansions and ensuring a secure, distortion-free structure.
Implementation Method 1
the insulating layer (9) made of insulating material arranged between these two cover plates (7, 8)... serves for thermal and/or acoustic insulation
Implementation Method 2
Under sunlight, the weather-facing paneling (paneling) can heat up and expand... thermally induced movements or expansions of the surrounding components
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a door leaf (4) with a surrounding door leaf frame (5) and a panel-shaped door infill (6). The door infill (6) has a first panel (7) and a second panel (8) spaced apart from it, wherein an insulating layer (9) is incorporated at least partially between the first and second panels (7, 8). According to the invention, the first panel (7) has an edge region (10) that projects beyond the insulating layer (9) and the second panel (8), and the door leaf (4) further comprises a connecting profile (12; 28; 36) which is connected to the first panel (7) at the surface (11) of the edge region (10) facing the insulating layer (9) and extends in the longitudinal direction of the edge region (10). The connecting profile (12; 28; 36) is designed to accommodate primary expansions/contractions in a vertical direction and secondary expansions/contractions in a horizontal plane.