Plastic panel door
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Solution Overview
Problem
Existing thermally insulated doors for refrigerated environments, particularly glass panel assemblies, are costly to manufacture and may not provide optimal thermal insulation or safety, while also limiting customization and energy efficiency.
Innovation Solution
A thermally insulated display case door design featuring a panel assembly with two transparent panes, flanges, and caps, allowing for customizable sizes during installation, improved thermal insulation, and enhanced safety with shatterproof plastic materials, along with a flexible wiper seal for better energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass panel assemblies are used for thermally insulated doors, then thermal insulation and safety are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from glass to plastic (acrylic or PETG), transforming the door assembly from fragile to shatterproof while maintaining transparency and improving safety in refrigerated environments
Solution Approach 2:
The patent creates a composite structure with multiple plastic layers (first and second transparent panes) bonded together with adhesive, forming a laminated assembly that provides both safety and thermal insulation properties
2Loss of energy
If custom-sized doors are manufactured, then fitment and energy efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the door into separate modular components (first transparent pane, second transparent pane, adhesive layers, edge seals) that can be independently manufactured and then assembled, allowing for easy customization of door dimensions without increasing overall manufacturing complexity
Solution Approach 2:
The patent enables dynamic sizing of the door assembly by allowing the individual panes and components to be manufactured in standard sizes and then cut or configured to specific custom dimensions during assembly, providing flexibility to match different opening sizes
3Reliability
If plastic panel doors are used, then safety and customization are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from glass to plastic (acrylic or PETG), transforming the door assembly from fragile to shatterproof while maintaining transparency and improving safety in refrigerated environments
Solution Approach 2:
The patent divides the door into separate modular components (first transparent pane, second transparent pane, adhesive layers, edge seals) that can be independently manufactured and then assembled, allowing for easy customization of door dimensions without increasing overall manufacturing complexity
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 provides cost-effective, customizable, and energy-efficient doors with improved thermal insulation and safety, enabling better fitment and visibility while reducing manufacturing costs and environmental impact.
Implementation Method 1
The second transparent pane is adhered to both flanges of the first pane
Implementation Method 2
thermally insulated doors for temperature controlled environments
Implementation Method 3
an edge guard coupled along an edge of at least one of the flanges, where the edge guard includes a flexible wiper configured to form a seal with another surface with the door in a closed position
Data Source
AI summary
A display case door includes a panel assembly with a first transparent pane and a second transparent pane. The first transparent pane includes flanges extending from each of a first edge and a second edge of a shaped portion. The second transparent pane is adhered to both flanges of the first pane to define a space between facing surfaces of the second transparent pane and the shaped portion of the first transparent pane and extending between openings at opposite ends of the panel assembly. Caps are coupled to the panel assembly and cover the openings at each of the first end and second end. The door further includes a hinge coupled to one of the flanges, a door handle secured to a surface of one of the flanges, and an edge guard coupled along an edge of at least one of the flanges.