Blow-Molded Roll-Up Door Panel With Reinforced Channels
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Solution Overview
Problem
Roll-up doors made of solid materials are heavy, requiring counter-balancing springs that reduce usable trailer volume and affect fuel efficiency, while existing lighter materials like extruded plastics need complex hinge systems and are difficult to repair.
Innovation Solution
Blow-molded thermoplastic panels with hollow channels and reinforcing members, such as steel or aluminum bars, that are inserted and shrunk-fit to enhance strength and durability, allowing for efficient assembly and repair, and are interchangeable with wooden panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid materials (wood) are used for roll-up door panels, then strength and durability are improved, but weight increases requiring counter-balancing springs that reduce usable trailer volume
Solution Approach 1:
The panel is divided into a hollow structure with internal channels that can accommodate reinforcing members. This segmentation allows the panel to maintain strength through the reinforcing members while the hollow structure reduces overall weight compared to solid wood panels.
Solution Approach 2:
The panel combines thermoplastic material with metal reinforcing members (steel or aluminum bars) to create a composite structure. This composite approach provides the strength of metal with the weight advantages of plastic, eliminating the need for counter-balancing springs.
2Weight of moving object
If lighter materials (extruded plastics) are used for panels, then weight is reduced, but device complexity increases due to complex hinge systems and difficulty in repair
Solution Approach 1:
The hinge mounting features are pre-formed as integral parts of the panel during the blow-molding process. This preliminary action eliminates the need for complex separate hinge systems and simplifies installation and repair, as panels can be easily replaced without complex disassembly.
3Weight of moving object
If hollow channels are formed in panels, then weight is reduced, but strength may be compromised without proper reinforcement
Solution Approach 1:
Metal reinforcing members (bars) are nested within the hollow channels of the thermoplastic panel. This nesting arrangement provides structural strength to the hollow panel, allowing it to maintain reduced weight while achieving the strength necessary for roll-up door applications.
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 lightweight, durable, and easily repairable roll-up doors that maintain trailer volume and fuel efficiency, with panels that can simulate a wooden appearance and replace traditional wooden panels for convenience.
Implementation Method 1
blow molding a hollow panel with a thermoplastic material in a mold cavity
Implementation Method 2
blow molding a hollow panel with a thermoplastic material in a mold cavity to form hollow, elongated channels
Implementation Method 3
inserted and shrunk-fit to enhance strength and durability
Data Source
AI summary
A roll-up door has a plurality of panels and a plurality of roller assemblies mounted to ends of the panels for mounting the panels in channels. At least some of the panels are formed of blow-molded thermoplastic material and have a relatively flat outside face and an inside face including ribs that extend longitudinally and transversely on the panel. A reinforced panel of thermoplastic material is made by blow molding a panel with a thermoplastic material to form a relatively flat outside face and a ribbed inside face, and with elongated channels along upper and lower walls thereof. The panel is trimmed while it is still warm to open the channels at one end. While the panel is still warm, reinforcing members are inserted into the elongated channels. The panels can be cooled to shrink the channels onto the reinforcing members.