Door Leaf Reinforcing Chamber Segmentation for Lock Case Stability
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Solution Overview
Problem
Modern plastic door systems with open-sided reinforcing elements lack stability, especially for large doors, due to the need for multiple recesses in the reinforcing profiles to accommodate the lock case, increasing assembly complexity and reducing stability.
Innovation Solution
The door leaf features a sash frame with a further reinforcing chamber in each profile spar, allowing a second circumferential reinforcing profile to be accommodated, which improves static properties and allows the other profile to remain unweakened, with cutouts only needed in one profile for the lock case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple recesses are created in the reinforcing profile to accommodate the lock case at different positions, then the lock case can be installed at almost any point along the reinforcement profile, but the stability of the door leaf frame is reduced
Solution Approach 1:
The reinforcing profile is segmented into two separate profiles: a first reinforcing profile that remains continuous and intact, and a second reinforcing profile that contains recesses at different positions. This segmentation allows the second profile to accommodate lock cases at various positions while the first profile maintains continuous structural support, resolving the contradiction between installation flexibility and frame stability.
2Adaptability or versatility
If recesses are created in the reinforcing profile for lock case installation, then the lock case can be accommodated, but the labor required during fabrication of the reinforcement profile increases
Solution Approach 1:
By dividing the reinforcing structure into two separate profiles with distinct functions, the manufacturing process is simplified. The first reinforcing profile can be produced as a continuous piece without complex cutouts, while the second profile can be separately fabricated with recesses at standard positions. This segmentation reduces overall fabrication complexity compared to creating multiple recesses in a single continuous profile.
3Device complexity
If a single reinforcing profile is used, then the structure is simpler, but the stability of large doors is insufficient
Solution Approach 1:
The reinforcing structure is divided into two separate reinforcing profiles that work together to provide enhanced stability for large doors. The first profile provides continuous structural support, while the second profile with its recesses provides additional anchoring points. This segmented approach delivers the increased strength required for large doors while maintaining reasonable structural simplicity.
Solution Approach 2:
The door leaf frame combines multiple materials including the hollow profile frame, filling element, and two reinforcing profiles (typically steel). This composite construction integrates materials with complementary properties to achieve the high strength and stability required for large doors, while the modular nature maintains manufacturing simplicity.
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a door leaf (3) comprising: - a leaf frame (6) formed from hollow profile mullions (61, 62, 63, 64); - a substantially circumferential reinforcing profile (16) received in a reinforcing chamber (15) of the leaf frame (6); and - a filling element (7) received in the leaf frame (6); wherein at least one profile mullion (63) of the leaf frame (6) comprises a further reinforcing chamber (17) in which a reinforcing profile (18) is received. Furthermore, the present invention relates to a door (1) comprising a frame (2) and a door leaf (3) according to the invention received in the frame (2).