Single-Panel Insulated Overhead Door for Seamless Thermal Sealing
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Solution Overview
Problem
Current insulated overhead doors in the cold storage industry are heavy, have a lower R-value, require complex hardware, and are costly to maintain, with multiple panels leading to air leaks, reduced thermal performance, and increased energy consumption.
Innovation Solution
A single-panel insulated overhead door made of a thermoplastic membrane with attached insulating material, designed to roll open and close in tracks, eliminating horizontal seams and using closed cell foam for improved insulation and reduced weight, allowing for easier installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If multiple hinged panels are used to construct the door, then the door can be opened and closed in tracks, but the door becomes heavy and requires complex hardware
Solution Approach 1:
The patent merges multiple separate panels into a single integrated panel construction. The door is formed as one continuous piece with insulation and facing materials bonded together, eliminating the need for multiple hinged sections while maintaining the ability to open and close in tracks through a single flexible panel design
2Ease of operation
If multiple hinged panels are used to construct the door, then the door can be opened and closed in tracks, but the door requires large numbers of hinges and hardware increasing maintenance costs
Solution Approach 1:
The patent combines multiple separate components into a single integrated door assembly. The facing, insulation, and sealing elements are bonded together as one unit, eliminating the need for numerous hinges, seals, and hardware components that would be required for multiple panel construction
Solution Approach 2:
The patent extracts and eliminates the complex hinge and hardware system from the door construction. By using a single flexible panel design, the door can open and close without requiring the extraction of individual panels connected by hardware, thus removing the maintenance burden of these components
3Area of stationary object
If multiple panels with horizontal seams are used, then the door can be constructed to fit the opening, but air leaks and heat intrusion occur reducing thermal performance
Solution Approach 1:
The patent merges multiple panel sections into a single continuous panel without horizontal seams. The insulation and facing materials are bonded together in one continuous construction, eliminating the seams where air leaks and thermal bridging would occur in multi-panel designs
Solution Approach 2:
The patent uses closed-cell foam insulation material that provides thermal resistance without air permeability. The closed-cell structure prevents air infiltration through the insulation layer, maintaining thermal performance while allowing the door to flex for opening and closing operations
4Loss of energy
If current insulated door materials are used, then the door provides insulation, but the R-value is lower than desired
Solution Approach 1:
The patent uses composite construction with multiple layers including outer facing, closed-cell foam insulation, and inner facing materials bonded together. This composite structure provides high R-value insulation while maintaining flexibility for door operation and reducing overall weight compared to traditional multi-panel insulated doors
Solution Approach 2:
The patent employs closed-cell foam insulation that provides superior thermal resistance per unit weight compared to open-cell or traditional insulation materials. The closed-cell structure traps air pockets that resist heat transfer, achieving high R-values without adding significant weight
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 higher R-value insulation, reduced weight, simplified maintenance, and lower energy consumption, while maintaining thermal performance and allowing for seamless decal application, and easier operation with reduced hardware needs.
Implementation Method 1
A single-panel insulated overhead door made of a thermoplastic membrane with attached insulating material... using closed cell foam for improved insulation and reduced weight
Data Source
AI summary
An article of manufacture for use as an insulated overhead door that is designed to roll open and closed in tracks, with a sheet of thermoplasitc material that acts as the outer door membrane and barrier to entry, a sheet of insulating material that acts as a base insulating barrier adhered to the thermoplastic membrane.