Door Shutter with Convex Block Pieces for Bendability

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Solution Overview

Problem

Existing door shutters with a bent design surface, when attempting to create an upwardly convex shape, compromise on bendability, limiting their cosmetic design possibilities.

Innovation Solution

A door shutter design featuring thin parts as plane surfaces and integrally formed, upwardly convex block pieces made of hard resin, which project from the underside of the main body, maintaining bendability while enhancing rigidity and allowing for a novel cosmetic appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If the design surface of the main body is made upwardly convex curved shape, then cosmetic appearance is improved, but bendability is impaired

Engineering Contradiction:

Improvedesign surface shapeVSAvoidbendability

Core Design Contradiction:

ShapeVSAdaptability or versatility

Solution Approach 1:

The main body is divided into multiple thin parts in the width direction, allowing each segment to bend independently while maintaining an upwardly convex curved shape on the design surface. This segmentation enables the shutter to achieve both aesthetic curvature and functional bendability along the guide groove.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the main body are given different properties: the design surface is formed with an upwardly convex curved shape for aesthetics, while thin parts are created to enable bending. This local differentiation allows simultaneous achievement of cosmetic appearance and bendability in different areas of the same component.

Inventive Principle:

Principle #3Local quality

2Strength

If block pieces are made larger to improve rigidity, then strength is improved, but bendability is impaired

Engineering Contradiction:

ImproverigidityVSAvoidbendability

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

Block pieces are positioned not only on the underside of the main body but also extend laterally beyond the thin parts. This three-dimensional arrangement provides rigidity support while allowing the main body to bend along the guide groove without restriction, as the block pieces do not interfere with the bending path.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If multiple materials are used for block pieces and main body, then rigidity and bendability are optimized, but manufacturing complexity is increased

Engineering Contradiction:

ImproverigidityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The block pieces and main body are integrally formed as a single component through two-material molding, combining the rigid block pieces and flexible main body in one manufacturing process. This integration eliminates separate assembly steps while maintaining the benefits of material differentiation for both rigidity and bendability.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7735538B2Door shutter

Publication Date: 2010.06.15 NIFCO INC

AI summary

While a bending ability is maintained, it is possible to provide an outer appearance which is not made possible in the past. A door shutter includes a main body on a design surface side which is bent in a width direction through thin parts, and plural block pieces disposed between the thin parts on an underside of the main body, wherein an opening on a device side is opened or closed by sliding along a guide groove on the device side. On the main body, the thin parts are formed as a plane surface, and parts overlapping with the block pieces are formed in an upwardly convex curved shape.