Hollow Ribbed Extruded Door Panels
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Solution Overview
Problem
Conventional doors with high mechanical or structural strength are often heavy and expensive to produce, and are difficult to adapt for specific entrance shapes or dimensions, making them inflexible and costly to manufacture.
Innovation Solution
A closure member formed by extrusion with a hollow interior partitioned by ribs, featuring textured panels and reinforcement means, allowing for adaptable and cost-effective production with integrated features like grooves for decoration and reinforcement, enhancing tensile strength and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional doors are made with high mechanical or structural strength, then strength is improved, but weight increases and production cost increases
Solution Approach 1:
The door is segmented into a hollow interior structure with multiple ribs positioned at intervals, dividing the interior space into discrete elongate spaces. This segmentation provides structural strength comparable to solid doors while using significantly less material, thereby reducing weight without compromising mechanical strength.
Solution Approach 2:
The door employs a composite construction combining the hollow interior structure with reinforcement means (such as steel bars or other strengthening elements) positioned within the hollow spaces. This composite approach achieves high mechanical strength with reduced material usage, lowering both weight and production cost.
2Strength
If conventional doors are made with high mechanical or structural strength, then strength is improved, but production cost increases
Solution Approach 1:
The hollow interior with partitioned ribs is formed in a single extrusion process, eliminating numerous subsequent steps such as trimming, edge beveling, and sanding that are required for conventional solid doors. This integrated forming process significantly reduces production time and labor costs while maintaining structural strength.
Solution Approach 2:
The extrusion process parameters are optimized to directly form the complex hollow interior structure with ribs and discrete spaces in one operation. This parameter optimization allows the door to achieve high structural strength without requiring multiple costly manufacturing steps, thereby reducing production cost.
3Ease of manufacture
If conventional doors are made with standard design, then production is straightforward, but adaptability to specific entrance shapes is poor
Solution Approach 1:
The extrusion process is made adaptable to different configurations, allowing the hollow interior structure, rib positioning, and panel dimensions to be dynamically adjusted according to specific entrance requirements. This enables the same manufacturing process to produce doors of various shapes and sizes without requiring complex retooling.
Solution Approach 2:
The extrusion process serves multiple functions: it forms the panels, creates the hollow interior, positions the ribs, and defines the overall door shape in a single operation. This universal process can accommodate different entrance configurations, making the manufacturing system versatile while maintaining production simplicity.
4Strength
If conventional doors use solid construction, then structural strength is achieved, but material usage increases
Solution Approach 1:
The solid construction is replaced with a segmented hollow interior structure containing multiple ribs that create discrete elongate spaces. This segmentation maintains structural strength by distributing loads across the rib framework while dramatically reducing the quantity of material required compared to solid door construction.
Solution Approach 2:
The door uses a composite structure combining the hollow interior framework with strategically positioned reinforcement means. This composite design achieves equivalent or superior structural strength to solid doors while using significantly less material, thereby reducing material usage and associated costs.
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 results in a flexible, adaptable, and cost-effective door with enhanced mechanical strength and thermal resistance, suitable for various applications while minimizing material usage and production costs.
Implementation Method 1
the panels, the ribs and the opposite end walls are formed by extrusion
Implementation Method 2
the hollow interior is occupied by reinforcement means
Implementation Method 3
at least one of the two panels is textured during the formation of the board to form a textured outer surface of the closure member
Data Source
AI summary
A closure member of a preferred configuration and the method of making the same. The closure member has a board with a major axis and two panels to sandwich a hollow interior that is partitioned by a plurality of ribs positioned at intervals within the hollow interior, the hollow interior is delimited in a first direction by a pair of opposite end walls. The hollow interior is accessible in a second direction which is substantially traverse to the first direction, and at least one of the two panels is textured during the formation of the board to form a textured outer surface of the closure member, or the hollow interior is filled with a preferred reinforcement means.