Modular Frame Rail Reinforcement for Impact-Resistant Doors
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Solution Overview
Problem
Multi-panel doors face challenges in meeting impact rating criteria and resisting high wind loads while maintaining an aesthetic appearance, as existing reinforcement methods are either unsightly or require complex manufacturing processes and inventory management.
Innovation Solution
A modular frame rail system with interchangeable reinforcement modules that can be slidably attached to the frame rails, providing varying levels of structural reinforcement as needed, allowing for a single type of frame rail to be used across different panels with different reinforcement modules added during assembly based on design loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker cross-section or stronger material frame members are used to meet impact rating criteria and resist high wind loads, then the structural strength is improved, but the aesthetic appearance is negatively affected and the weight is substantially increased
Solution Approach 1:
The frame member is divided into a base frame member and separate reinforcement members that can be independently selected and attached. This segmentation allows the base frame to maintain aesthetic appearance while reinforcement members provide the necessary structural strength to meet impact rating criteria and resist high wind loads.
Solution Approach 2:
Reinforcement members are selectively applied to specific portions of the frame where additional strength is needed based on local load requirements. This allows different regions of the frame to have different structural properties, with reinforcement concentrated in areas experiencing higher loads while maintaining aesthetic appearance in visible areas.
2Adaptability or versatility
If different types of frame members with different structural properties are used to accommodate different design loads, then the adaptability is improved, but the manufacturing complexity and inventory management are increased
Solution Approach 1:
A single base frame member design serves multiple functions by accommodating different reinforcement members through standardized attachment mechanisms. This universal base frame can be used across all panels, while the reinforcement members are selectively added based on specific load requirements, reducing the need for multiple specialized frame types.
Solution Approach 2:
The frame system transitions from a static, fixed configuration to a dynamic, configurable system where reinforcement members can be selectively attached or removed based on changing design requirements. This allows the same base frame to adapt to different load conditions without requiring different manufacturing processes.
3Strength
If add-on structural reinforcement such as steel struts are used, then the structural strength is improved, but the aesthetic appearance is degraded and the number of visible fasteners is increased
Solution Approach 1:
The reinforcement members are integrated with the base frame member through standardized attachment mechanisms that combine structural function with aesthetic consideration. The reinforcement members are designed to attach in a way that minimizes visible fasteners and maintains a sleek appearance, merging the structural reinforcement function with the aesthetic requirements of the full view door design.
Data Source
AI summary
A frame rail for a movable barrier includes a top side, a bottom side, a front side, and a rear side. A first module connector is formed on the rear side. The first module connector extends continuously along a length of the frame rail and is configured to slidably receive a corresponding second module connector of a module. The frame rail has a continuous cross-section with the first module connector integrally formed with the top, bottom, front, and rear sides. One of the first or second module connectors comprises a groove and the other of the first or second module connectors comprises a tongue configured for receipt within the groove. The first module connector is configured to slidably receive the second module connector from a longitudinal end surface of the frame rail.