Integrally Hinged Stile for Bi-Fold Doors
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Solution Overview
Problem
Current designs of folding doors face challenges in achieving thermal efficiency while maintaining a durable and strong hinging mechanism, as thermally conductive hinges can short circuit thermal breaks and compromise energy efficiency.
Innovation Solution
The integration of an integral hinge assembly with opposing flanges and gears into the door stile, where the flanges are oriented to align thermal breaks and interlace cogs, eliminating the need for fasteners and creating a continuous, durable connection that does not bridge thermal breaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermally conductive hinges are installed to the door stile, then a durable and strong hinging mechanism is achieved, but thermal breaks are short circuited and thermal efficiency is compromised
Solution Approach 1:
The hinge assembly is divided into multiple segments including a first flange, a second flange, a knuckle, and a thermal break component. This segmentation allows the hinge to maintain structural integrity and durability while incorporating thermal breaks to prevent heat transfer between the interior and exterior of the door.
Solution Approach 2:
A thermal break component is introduced as an intermediary element between the first flange and the second flange. This thermal break acts as a mediator that prevents direct thermal conduction through the hinge assembly, thereby maintaining thermal efficiency while still allowing the hinge to function as a durable connecting mechanism.
2Strength
If the length of the hinge within the door is extended to make the hinge flange larger, then the door assembly becomes more durable and strong, but the complexity of maintaining thermal breaks increases
Solution Approach 1:
The hinge assembly merges multiple functions into a single integrated structure. The first flange, second flange, knuckle, and thermal break are combined into one cohesive assembly that provides both structural strength and thermal insulation in a unified component, reducing the complexity of aligning separate thermal break elements.
Solution Approach 2:
The hinge assembly serves multiple functions simultaneously: it provides the mechanical hinging function for door operation, maintains structural strength through its extended flange design, and incorporates thermal insulation through the integrated thermal break component. This multi-functionality eliminates the need for separate thermal break alignment procedures.
3Loss of energy
If thermal breaks are aligned in a single plane within the door to achieve optimal thermal efficiency, then thermal performance is maximized, but the installation of thermally conductive hinges becomes conflicted
Solution Approach 1:
The thermal break is pre-integrated into the hinge assembly during manufacturing, with the thermal break component already positioned between the first flange and the second flange. This preliminary action ensures that thermal breaks remain aligned in a single plane while simplifying installation, as the hinge assembly arrives as a complete, pre-configured unit requiring no separate thermal break alignment.
Data Source
AI summary
A hinge for a bi-fold door is integrated with a pair of stiles. Each stile has a hinge flange integrated to the stile. Opposing stiles with opposing and aligned hinge flanges collectively create an integral hinge assembly that may be useful in thermal doors employing one or more thermal breaks.