Sheet Metal Door Leaf with Laminated Wood Insert
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Solution Overview
Problem
Existing door leaves face challenges in achieving high thermal insulation and burglary resistance while maintaining a simple and cost-effective structure, with wooden doors requiring frequent maintenance and being prone to distortion due to temperature fluctuations.
Innovation Solution
A door leaf design featuring a sheet metal outer casing with a laminated wood insert element and a plastic film element, providing enhanced thermal insulation, stability, and burglary security, along with a method for manufacturing that includes applying the film element to the outer surface of the insert element and integrating it into the sheet metal shell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wooden doors are used for entrance doors, then they provide good thermal insulation and aesthetic appearance, but they require frequent maintenance and are prone to distortion due to temperature fluctuations
Solution Approach 1:
The door leaf combines sheet metal outer casing with wooden insert elements and foam core material to create a composite structure. The sheet metal provides dimensional stability and resistance to temperature-induced distortion, while the wooden inserts maintain thermal insulation properties. This composite construction eliminates the need for frequent maintenance while preserving the thermal performance of wood.
2Stability of the object's composition
If sheet metal outer casing is used, then dimensional stability and resistance to mechanical stress are improved, but thermal insulation performance may be reduced due to metal's high thermal conductivity
Solution Approach 1:
The sheet metal outer casing encloses and protects the thermal insulation core material and wooden insert elements. The nested structure allows the metal casing to provide mechanical strength and dimensional stability while the inner core materials maintain thermal insulation performance, preventing heat transfer through the door leaf.
Solution Approach 2:
The combination of sheet metal outer casing with foam core material and wooden inserts creates a composite structure where each material contributes its superior properties: metal provides structural stability, foam provides thermal insulation, and wood adds aesthetic quality and additional insulation.
3Reliability
If a complex multi-component structure is used to achieve high burglary resistance and thermal insulation, then security and insulation performance are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The door leaf is divided into distinct functional segments: sheet metal outer casing for security and structure, foam core material for thermal insulation, and wooden insert elements for aesthetics and additional insulation. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process through standardized production of individual parts.
Data Source
Figure 1
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AI summary
The invention relates to a door leaf (10) for an entrance door. The door leaf (10) comprises an outer casing (18) which covers at least the broad sides (16, 17) of the door leaf (10), wherein the outer casing (18) is made of a metal sheet. Furthermore, the door leaf (10) comprises an insert element (21) which is at least partially surrounded by the outer casing (18) and is arranged on an end face (11) of the door leaf (10), wherein the insert element (21) is made of laminated wood. A foil element (44) is also applied to an outer surface of the insert element (21) facing the end face (11) of the door leaf (10).