Impact Resistant Door Facing Using Polymeric Composite
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Solution Overview
Problem
Conventional impact-resistant doors are either expensive, heavy, difficult to assemble and install, and lack aesthetic appeal, while existing solutions either use costly materials like metal or complex cementitious designs that are hard to store and transport.
Innovation Solution
A rectangular sheet of molded hardened polymeric material with a continuous, porous mat integrally molded into it, allowing the polymeric material to permeate and bind with the mat before hardening, providing a strong and aesthetically pleasing impact-resistant door facing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional core materials (corrugated cardboard, paper, foam, fiberboard) are used to fill hollow spaces, then the door is lightweight and easy to manufacture, but the door lacks impact resistance and cannot withstand hurricane conditions
Solution Approach 1:
The patent uses a composite material system consisting of a polymeric facing material integrated with a continuous mat structure. The mat is impregnated with polymeric resin to form a composite that provides both structural integrity and impact resistance. This composite construction allows the door to withstand hurricane impacts while maintaining the benefits of polymeric materials.
Solution Approach 2:
The continuous mat used in the invention has a porous structure that allows it to be impregnated with polymeric resin. This porosity enables the resin to penetrate and bond with the mat fibers, creating a strong integrated structure that provides impact resistance while maintaining lightweight properties.
2Strength
If metal door facings are used, then impact resistance is improved, but cost increases, aesthetic detail is reduced, and susceptibility to rust and dents occurs
Solution Approach 1:
The patent employs a composite material system where a continuous mat is impregnated with polymeric resin to create a fiber-reinforced plastic structure. This composite provides metal-like impact resistance while maintaining the aesthetic advantages of polymeric materials and eliminating corrosion issues.
Solution Approach 2:
The invention changes the material parameters by using a continuous mat with specific porosity that allows optimal impregnation with polymeric resin. This parameter optimization achieves the desired balance between impact resistance and aesthetic quality without requiring metal materials.
3Strength
If cementitious material is poured around a mat in the door cavity, then impact resistance is achieved, but the door becomes heavy and difficult to store, transport, and install
Solution Approach 1:
The patent uses a composite material system where a continuous mat is impregnated with polymeric resin within the door cavity. This composite provides impact resistance comparable to cementitious materials but with significantly reduced weight, making the door easier to store, transport, and install.
Solution Approach 2:
The invention replaces heavy, permanent cementitious materials with a lighter polymeric composite that achieves the same protective function. The polymeric material provides sufficient impact resistance for hurricane conditions without the excessive weight and handling difficulties of cement-based solutions.
4Strength
If a continuous mat is integrally molded into the polymeric sheet, then impact resistance and structural integrity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by placing the continuous mat into the mold cavity before injecting the polymeric resin. This preliminary positioning of the mat allows it to be integrated into the structure during the molding process, achieving strong structural integrity without requiring complex post-processing or assembly steps.
Solution Approach 2:
The continuous mat is selected with appropriate porosity to facilitate impregnation with polymeric resin during molding. This porosity allows the resin to penetrate and bond with the mat fibers, creating a strong integrated structure through a relatively simple one-step molding process rather than requiring complex multi-stage manufacturing.
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 door facing with significantly higher impact strength, passing ASTM and Dade County hurricane tests, while being cost-effective, lightweight, and easy to install, with a surface finish suitable for exterior use.
Implementation Method 1
The mat is sufficiently porous to allow the polymeric material to permeate the mat during the compression process
Implementation Method 2
A mat having a continuous structure is integrally molded into the sheet. The mat is sufficiently porous to allow the polymeric material to permeate the mat prior to the polymeric material having hardened
Data Source
AI summary
The present invention is directed to an impact resistant door facing. The facing includes a rectangular sheet of molded hardened polymeric material having first and second opposing major surfaces. A mat having a continuous structure is integrally molded into the sheet. The mat is sufficiently porous to allow the polymeric material to permeate the mat prior to the polymeric material having hardened. The mat is disposed within the sheet so that at least one of the major surfaces is unbroken. The present invention also relates to a method of forming the disclosed door facing, and a door formed therewith.