Seamless Composite Door Panel with Folded Edges
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Solution Overview
Problem
Conventional door construction methods result in exposed raw edges that require painting, and existing solutions do not provide a seamless appearance for all visible surfaces, including the latched side face.
Innovation Solution
A door formed from a single composite aluminium panel with parallel V-shaped grooves and triangular cutouts, allowing the panel to be folded into a seamless configuration with no visible joins on the main and latched faces, using an inner and outer metal sheet with a plastics core and a frame of hollow C-shaped beams for structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional door construction with timber or MDF frame and honeycomb insert is used, then the door can be manufactured with traditional materials and processes, but the door ends are exposed in raw state requiring painting and the construction is complex with multiple components
Solution Approach 1:
The patent merges the door frame, panel, and finishing into a single pre-finished composite panel structure. The aluminum panel with integrated skin and core eliminates the need for separate timber/MDF frame construction, honeycomb inserts, and subsequent painting operations, thereby simplifying manufacturing while reducing structural complexity
Solution Approach 2:
The door panel is pre-finished at the factory with all surfaces including edges and ends completely finished before installation. This preliminary action eliminates the need for on-site painting and finishing work, simplifying both manufacturing processes and installation procedures
2Ease of manufacture
If pre-finished material is used for door surfaces, then the external surface is pre-finished, but the door ends remain exposed in raw state requiring painting
Solution Approach 1:
The patent combines the panel body and edge finishes into a single integrated pre-finished composite structure. The aluminum panel construction with skin and core provides continuous finishing across all surfaces including previously problematic ends and edges, eliminating the need for separate finishing operations on door ends
3Ease of operation
If traditional door construction is used, then the door has functional surfaces, but the latched side face and other non-visible surfaces require additional finishing work
Solution Approach 1:
The patent applies preliminary finishing to all surfaces of the door panel including latched side face, hinge face, top, bottom, and end surfaces during factory manufacturing. This complete pre-finishing of all surfaces regardless of visibility eliminates the need for additional on-site finishing work, greatly simplifying installation
4Shape
If folded panels with V-shaped grooves are used as in prior art, then some external panels have pre-finished surfaces, but joining seams are visible in the main surface
Solution Approach 1:
The patent merges multiple panel sections into a single continuous pre-finished aluminum panel construction. By eliminating separate panel joins and using a unified panel structure with integrated folds, the invention achieves seamless appearance without visible joining seams while reducing the complexity of panel joining operations
Data Source
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AI summary
A door (100) comprising a single panel (20) folded to form a latch face (53) and first and second main faces (52, 54) of the door. The door preferably further comprises edge tabs (36) folded to form upper, lower and hinge faces of the door. The panel is preferably a composite panel comprising an inner metal sheet (65), an outer metal sheet (66), and a plastics core material (67) between the metal sheets.