Door Leaf Skeleton Using Segmented Wooden Profiles
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Solution Overview
Problem
Existing door leaf manufacturing processes are complex and costly, with lightweight versions lacking stability and heavy versions being expensive, while also requiring complex manufacturing processes.
Innovation Solution
A method and device for producing a door leaf with a flexible composite insert of profile elements, such as wooden strips or rods, which provides high stability and can be easily integrated into a prefabricated frame using a flexible connection, reducing costs and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight inserts (honeycomb, tubular chipboard) are used, then the door leaf weight is reduced, but the stability is insufficient
Solution Approach 1:
The patent uses composite materials by combining wooden profile elements with flexible connecting pieces to create an insert that achieves both lightweight properties and high stability. The wooden profiles provide structural rigidity while the flexible connectors allow assembly, creating a composite structure that outperforms both solid wood and traditional lightweight inserts.
Solution Approach 2:
The insert is segmented into multiple wooden profile elements (longitudinal and transverse profiles) connected by flexible connecting pieces. This segmentation allows the creation of a lightweight structure that maintains stability through the distributed framework, avoiding the need for solid heavy materials.
2Stability of the object's composition
If heavy-duty inserts (solid chipboard) are used, then the door leaf stability is high, but the manufacturing cost increases
Solution Approach 1:
Instead of using solid chipboard, the patent segments the insert into multiple wooden profiles connected by flexible pieces. This segmentation reduces material costs and manufacturing complexity while maintaining stability, as the framed structure achieves rigidity without requiring solid dense materials.
Solution Approach 2:
The patent changes the structural parameters from solid mass (chipboard) to a framed configuration with specific profile dimensions and spacing. This parameter change allows achieving the required stability with less material and simpler manufacturing processes, reducing overall cost.
3Manufacturing precision
If complex manufacturing processes are used, then the door leaf quality is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent introduces flexible connecting pieces that enable dynamic assembly processes. The flexible connectors allow the profile elements to be easily joined and adjusted during manufacturing, simplifying the production process while maintaining high quality standards through precise profile design.
Solution Approach 2:
The wooden profiles and flexible connecting pieces are designed and pre-prepared in advance with specific dimensions and connection features. This preliminary preparation of components simplifies the final assembly process, allowing high-quality door leaves to be manufactured efficiently without complex in-process operations.
Data Source
Figure 1a
Figure 1b
Figure 2~5b
AI summary
The invention relates to a method for manufacturing a door (1), in particular a door leaf (1), with an insert (2) for insulation and/or stabilization, wherein the door leaf (1) is coated with door cover plates (3). According to the method according to the invention, for the production of a door leaf (1), it is proposed that in a first step several parallel transverse or longitudinal profile elements (4, 5) are attached between two longitudinally or transversely arranged profile elements (4, 5) to form a skeleton (6), into which an insert for insulation and/or stabilization can optionally be placed, and wherein the constructed skeleton (6) is then calibrated to dimensions in a second step, and wherein the door cover plates (3) are then applied in a third step.