Thermal Break Door Frame and Insulated Panel Design

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Solution Overview

Problem

Commercial door openings experience thermal and air leakage, leading to increased energy costs, condensation, frost buildup, and thermal bow due to temperature differences between building exteriors and interiors, causing damage and deformation.

Innovation Solution

A metal door frame with thermally insulative layers between steel segments and an insulated door panel featuring stiffeners and hardenable insulation material for thermal insulation and structural reinforcement, eliminating the need for metal fasteners to reduce thermal conductivity and enhance rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal door frames and panels are used for structural strength, then strength and rigidity are improved, but thermal conductivity increases causing heat loss and thermal bow

Engineering Contradiction:

Improvestructural strengthVSAvoidthermal conductivity

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The door frame is divided into inner and outer frame segments separated by a thermal break layer. This segmentation interrupts the continuous metal path that would otherwise conduct heat, allowing the metal segments to maintain structural strength while the thermal break reduces thermal conductivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The door assembly uses composite construction combining metal frame segments with a thermal break material (such as rubber, plastic, or foam) and insulation material. This composite structure leverages the strength of metal while incorporating materials with low thermal conductivity to reduce heat transfer.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If metal fasteners are used to assemble door components, then ease of manufacture is improved, but thermal conductivity increases due to metal-to-metal contact

Engineering Contradiction:

Improveease of assemblyVSAvoidthermal conductivity

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The thermal break layer acts as an intermediary between metal fasteners and door components, preventing direct metal-to-metal contact. This intermediary layer maintains the ease of mechanical assembly while interrupting the thermal conduction path that would otherwise exist through the fastener.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If door frames are designed without thermal breaks, then device complexity is reduced, but condensation and frost buildup occur due to thermal losses

Engineering Contradiction:

Improveframe structure complexityVSAvoidcondensation and frost

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The frame is segmented into thermal zones separated by the thermal break, preventing the continuous cold path that leads to condensation and frost. This segmentation adds minimal complexity while effectively addressing the harmful thermal effects.

Inventive Principle:

Principle #1Segmentation

4Loss of energy

If thick insulation material is added to reduce thermal conductivity, then thermal efficiency is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvethermal efficiencyVSAvoidinsulation structure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

Instead of uniformly thick insulation throughout the entire door assembly, the patent applies insulation strategically at key thermal bridge locations and uses a thermal break at the frame level. This localized approach provides effective thermal protection while minimizing the overall complexity and volume of insulation material required.

Inventive Principle:

Principle #3Local quality

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 effectively reduces thermal conductivity, prevents air infiltration, and resists thermal bow, improving energy efficiency, structural integrity, and aesthetics while minimizing the risk of damage from temperature extremes.

Implementation Method 1

a thermally insulative layer between the at least one first door frame segment and the at least one second door frame segment

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

a hardenable insulation material between adjacent exterior panels, stiffeners and frame members in the shell interior portion

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10704317B2Insulated reinforced door panel and door frame with thermal break

Publication Date: 2020.07.07 AADG INC

AI summary

A metal door frame for a door opening comprising at least one first door frame segment for upper or side portions of the door opening, the at least one first door frame segment having a first molding flange, a first jamb face adjacent to the molding flange, and a first stop flange adjacent to the jamb face. The metal door frame includes at least one second door frame segment for upper and side portions of the door opening, the at least one second door frame segment having a second molding flange, a second jamb face adjacent to the molding flange, a second stop flange adjacent to the jamb face, a second stop face adjacent to the stop flange, and a third stop flange adjacent to the stop face. The metal door frame includes a thermally insulative layer between the first door frame segment and the second door frame segment.