Entryway Sealing Spacer with Compression Control Inserts
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Solution Overview
Problem
Existing sealing methods for entryways, such as caulk and gaskets, are ineffective due to variable compression during installation, wear, and material hardening, leading to water infiltration and structural degradation over time.
Innovation Solution
A sealing spacer with a compressible gasket and harder inserts, where the gasket is made from a soft durometer material and includes apertures for inserts of a harder durometer, controlling compression to ensure a consistent seal between entryway components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a compliant sealing portion with high compressibility is used to seal gaps between entryway components, then the sealing effectiveness is improved, but the compression control becomes difficult resulting in over-compression or under-compression
Solution Approach 1:
The sealing spacer combines a compliant sealing portion made of soft compressible material (first durometer) with a less compliant compression control portion made of harder material (second durometer). This composite structure allows the soft sealing portion to provide effective sealing while the hard control portion maintains its shape and provides predictable compression control during installation, preventing over-compression or under-compression.
2Reliability
If sealing gaskets are used to seal gaps in entryways, then water resistance is improved, but the gaskets suffer from high wear rates and material hardening over time
Solution Approach 1:
The sealing spacer applies local quality by having different durometer values in different portions of the same component. The compliant sealing portion (softer material) maintains elasticity and sealing effectiveness, while the less compliant compression control portion (harder material) provides structural stability and wear resistance. This localized differentiation allows each portion to optimize its function for longevity.
3Reliability
If caulk is applied to seal gaps between hard surfaces in entryways, then water resistance is achieved, but the sealing requires precise application and rework is difficult
Solution Approach 1:
The invention extracts the sealing function from the traditional caulk application method and integrates it into a pre-formed sealing spacer component. The spacer includes a compliant sealing portion that provides the water-resistant seal, while the less compliant compression control portion provides structural support and compression control. This extraction allows the sealing to be achieved through a single installation step rather than requiring precise caulk application and potential rework.
4Ease of manufacture
If a uniform thickness gasket is used for sealing, then manufacturing is simplified, but compression distribution is uneven leading to sealing failures
Solution Approach 1:
The sealing spacer is segmented into distinct functional portions: a compliant sealing portion with specific thickness for sealing, and a less compliant compression control portion with different thickness for structural support. This segmentation allows each portion to be optimized for its specific function while maintaining manufacturability through standard molding processes for multi-section components.
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 seals gaps between entryway components, preventing water and air infiltration while maintaining flexibility and durability, thus extending the structural integrity of the door unit assembly.
Implementation Method 1
a gasket made from a compressible material with a first durometer
Implementation Method 2
The at least one insert has an insert thickness, the insert thickness is less than the uncompressed gasket thickness
Data Source
AI summary
A gasket for an entryway is described that includes a compliant sealing portion having an uncompressed gasket thickness and a less compliant compression control portion having opposing exposed surfaces. A perimeter of the less compliant compression control portion is surrounded by the compliant sealing portion. A thickness of the less compliant compression control portion is less than the uncompressed gasket thickness.