Door Leaf Profile Single Fastening Web Mechanical Assembly
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Solution Overview
Problem
Existing door leaf manufacturing methods face challenges with adhesive hardening times, complex and costly designs, and unsightly visual appearances due to massive profiles and additional holding elements.
Innovation Solution
A door leaf design featuring a casement profile with a single fastening web and mechanical connecting elements, such as screws or rivets, that are anchored into an inner shell, allowing for quick and cost-effective assembly without special components, and an optional second insulating layer for improved thermal insulation and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to attach the casement profile to the sandwich panel, then a firm connection is achieved, but the door leaf cannot be installed immediately due to hardening time and production costs increase
Solution Approach 1:
The patent replaces the chemical bonding system (adhesive) with a mechanical fastening system. The casement profile includes a fastening web with recesses that receive mechanical connecting elements (screws, rivets, or locking connections) which engage directly with the sandwich panel, eliminating the need for adhesive hardening time while maintaining connection strength.
Solution Approach 2:
The patent extracts the adhesive bonding function from the connection system and replaces it with dedicated mechanical fastening features integrated into the casement profile structure. The fastening web with its recesses provides a specialized zone for mechanical attachment, separating the structural connection function from the panel bonding function.
2Strength
If a massive leaf profile design is used to ensure structural integrity, then connection strength is improved, but the visual appearance becomes negative and device complexity increases
Solution Approach 1:
The casement profile is segmented into distinct functional zones: a structural core for strength, a fastening web with integrated recesses for mechanical connection, and a thin cosmetic cover for visual appearance. This segmentation allows each part to optimize its specific function without compromising the others, reducing overall profile mass while maintaining structural integrity and aesthetic quality.
Solution Approach 2:
The patent applies different properties to different parts of the casement profile: the fastening web region has enhanced structural properties with integrated recesses for mechanical fastening, while the visible cover portion is optimized for aesthetic appearance with thin walls. This local differentiation eliminates the need for a uniformly massive profile throughout.
3Adaptability or versatility
If additional holding elements are added to the surface element for fastening, then connection capability is improved, but production complexity and costs increase
Solution Approach 1:
The patent merges the fastening function directly into the casement profile structure itself. The fastening web with its recesses is an integral part of the profile extrusion, combining the structural support function and the fastening function into a single integrated component. This eliminates the need for separate holding elements that would need to be attached to the panel, simplifying both manufacturing and assembly.
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
A door leaf (2) with a leaf frame (5) which is assembled from sections of a leaf frame profile (6, 6a, 6b) and a filling (7) which has an inner shell (8a) and an outer shell (8b) and a heat-insulating core (9) arranged between the shells (8a, 8b), wherein the leaf frame (5) is connected to the filling (7) by means of mechanical connecting elements, is characterized in that the leaf frame profile (6, 6a, 6b) has a single fastening web (32) via which the leaf frame profile (6, 6a, 6b) and thus the leaf frame (5) is positively connected to the filling (7) by means of the mechanical connecting elements.