Modular Sliding Door Header with Thermal Breaks

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Solution Overview

Problem

Conventional headers for sliding doors and windows face challenges in customization and thermal efficiency, making them difficult to adapt to changes in the number of sliding panels and resulting in poor performance.

Innovation Solution

A modular header system comprising left and right header pieces connected by thermal connectors and extenders, allowing for adjustable width and height, improved thermal efficiency through thermal connectors, and integration of features like protrusions, crosspieces, and thermal breaks to enhance heat dissipation and accommodate various configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional stock rectangular bars with ninety-degree angle extrusions are used for headers, then manufacturing is simple and cost-effective, but customization for different numbers of sliding panels is difficult and thermal efficiency is poor

Engineering Contradiction:

Improvecustomization for different panel configurationsVSAvoidheader structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The header is divided into multiple separate pieces (first header piece, second header piece, third header piece) that can be independently selected and combined. Each piece can be configured for specific numbers of sliding panels (e.g., first piece for one panel, second piece for two panels, third piece for three or more panels), allowing easy customization without creating a completely new header structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The header pieces are designed with universal features that allow them to serve multiple functions. The pieces can be used in different combinations to accommodate various numbers of sliding panels, and the track assembly can function both as a structural support and as a thermal break component, reducing the need for separate specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional solid bar headers are used, then structural strength is adequate, but thermal efficiency is poor due to lack of thermal breaks

Engineering Contradiction:

Improvethermal efficiencyVSAvoidheader structural strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

A thermal break assembly is introduced as an intermediary component between the header pieces. This assembly includes a track portion and a thermal break portion that physically connects the header pieces while providing thermal insulation. The thermal break assembly acts as a mediator that maintains structural continuity while preventing heat transfer through the header.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The header system uses composite construction combining different materials with complementary properties. The header pieces are made of structurally strong materials (such as aluminum or steel), while the thermal break portion uses insulating materials (such as plastic or composite materials with low thermal conductivity). This composite approach allows the header to achieve both high structural strength and high thermal efficiency.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If modular header pieces are used for customization, then adaptability to different panel configurations is improved, but assembly complexity increases

Engineering Contradiction:

Improveadjustability to panel configurationsVSAvoidassembly simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The connection features are merged directly into the header pieces themselves rather than being separate components. The first header piece includes a first connection feature, the second header piece includes a second connection feature, and the third header piece includes a third connection feature. These integrated connection features simplify assembly by eliminating the need for separate fasteners or coupling mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The header system is designed to be dynamically configurable rather than statically fixed. The modular pieces can be easily assembled and disassembled to adapt to different installation requirements. The connection features are designed to facilitate quick assembly and reconfiguration, allowing the header system to dynamically adjust to various panel configurations without complex tools or procedures.

Inventive Principle:

Principle #15Dynamics

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 modular header system enables easy customization and improved thermal efficiency, accommodating different panel configurations while minimizing friction and optimizing heat dissipation, thus addressing the limitations of conventional headers.

Implementation Method 1

thermal connectors and extenders, allowing for adjustable width and height, improved thermal efficiency through thermal connectors

Methodology Applied

Scientific EffectThermal break: Thermal Insulation

Implementation Method 2

integration of features like protrusions, crosspieces, and thermal breaks to enhance heat dissipation

Methodology Applied

Scientific EffectHeat dissipation: Convection

Data Source

PatentUS11680438B2Adjustable header for sliding doors and windows

Publication Date: 2023.06.20 GOLDBRECHT LLC

AI summary

An adjustable header having a first header piece and a second header piece, which are attachable to each other by a connector.