Rechargeable Door Assembly for Integrated Device Power Transfer

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Solution Overview

Problem

Existing exterior and interior doors for residential or commercial buildings with integrated electric devices face challenges in power management due to the need for multiple batteries, which are unattractive, require frequent replacement or charging, and complicate retrofitting with AC power, impacting structural integrity, insulation, and aesthetics.

Innovation Solution

A door assembly with a rechargeable power source integrated into the door slab, utilizing a rechargeable battery housed within a hollow cavity, connected to external rechargeable batteries via magnetic or wired connections for seamless power transfer, allowing for wireless or wired charging without AC power retrofitting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate battery packs are used for different electric devices on the door, then each device can be powered independently, but power management becomes difficult and cumbersome

Engineering Contradiction:

Improvedevice power independenceVSAvoidpower management complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent consolidates multiple separate battery packs into a single integrated rechargeable battery system housed within the door assembly. This single battery pack powers all electric devices (smart lock, camera, intercom, sensors) through a unified power management circuit, eliminating the need to manage multiple separate batteries while maintaining independent device operation.

Inventive Principle:

Principle #5Merging (Combining)

2Power

If AC line current is supplied to power door devices, then electric operating capability is enhanced, but retrofitting existing walls and door frames increases component costs and creates scheduling issues

Engineering Contradiction:

Improveelectric operating capabilityVSAvoidretrofitting complexity

Core Design Contradiction:

PowerVSEase of manufacture

Solution Approach 1:

The patent extracts the power supply requirement from the building's AC infrastructure and relocates it to a self-contained rechargeable battery system integrated into the door assembly. This allows the door to operate independently without requiring AC power wiring through walls and door frames, eliminating retrofitting complexity while maintaining full electric device functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If electric devices are mounted to the door with separate battery packs, then desired functions are provided, but the appearance becomes unattractive and unpleasant

Engineering Contradiction:

Improvedevice functionalityVSAvoidaesthetic appearance

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The patent merges all battery packs and power management components into a single concealed compartment within the door assembly. The unified battery housing is designed to be aesthetically pleasing and blend with the door's appearance, eliminating the visual clutter of multiple separate battery packs mounted on the door surface while maintaining all required device functions.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple different battery packs are used for different electric devices, then each device can be powered, but the need for multiple batteries renders power management difficult and cumbersome

Engineering Contradiction:

Improvedevice power supplyVSAvoidpower management ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent implements a self-service power management system where the single rechargeable battery pack automatically recharges itself through wireless charging when placed near a charging base, or through wired connection. The system includes automatic battery level monitoring, device power management, and seamless switching between devices, eliminating the need for user intervention in power management tasks.

Inventive Principle:

Principle #25Self-service

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

Provides continuous power to electric devices while maintaining the door's structural integrity, insulation, and aesthetics, simplifying power management by integrating a single rechargeable battery system that can be easily maintained without AC power retrofitting.

Implementation Method 1

connected to external rechargeable batteries via magnetic or wired connections for seamless power transfer

Methodology Applied

Scientific EffectMagnetic connection: Magnetism

Data Source

PatentUS20250334001A1Door assembly with rechargeable electrical power supply for integrated electric devices and methods thereof

Publication Date: 2025.10.30 MASONITE CORP

AI summary

Aspects of the present disclosure describe a rechargeable door that includes at least one internal rechargeable battery and at least one further DC component powered by such rechargeable battery, wherein the at least one internal rechargeable battery is configured to be recharged via a physical connection, such as wired connections, or other contacts such as magnetic contacts or pogo pins or spring contacts, in the door via a second rechargeable battery or via wireless recharging, for example magnetic inductive or resonance charging, via placement of the second rechargeable battery on or within the door.