Thermally Broken Door Panel With Dual Support Connector
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Solution Overview
Problem
Conventional door assemblies fail to efficiently transfer energy away from the front to the back of the door, leading to issues such as increased energy consumption, risk of injury from metal connections, and vulnerability to forced entry and severe weather conditions.
Innovation Solution
A thermally broken door panel with a dual support connector assembly that includes a thermal break core and rigid thermal break edges, preventing direct metal-to-metal contact between the front and back metal panels, and utilizing a dual support connector system between the door and glass pane without corner clips, allowing for secure attachment and easy cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional door assembly with direct metal-to-metal connection is used, then structural strength and simplicity are improved, but energy transfer efficiency deteriorates and safety risks increase
Solution Approach 1:
A non-metallic thermal break core is introduced as an intermediary component between the front and back metal panels. This thermal break core prevents direct metal-to-metal contact, thereby reducing thermal energy transfer while maintaining the structural integrity of the door assembly through its rigid construction.
Solution Approach 2:
The door assembly employs a composite structure combining metal panels with a non-metallic thermal break core. This composite design leverages the strength of metal while incorporating the thermal insulation properties of non-metallic materials, achieving both structural strength and energy efficiency.
2Device complexity
If a conventional door assembly with direct metal-to-metal connection is used, then structural simplicity is improved, but safety risks from burns and frost injuries increase
Solution Approach 1:
The thermal break core serves as a protective intermediary that interrupts the thermal pathway between the exterior and interior metal surfaces. This prevents harmful thermal energy transfer that could cause burns or frost injuries to users, while the overall structural design remains relatively simple.
3Ease of manufacture
If a conventional door assembly with corner clips is used, then ease of manufacture is improved, but resistance to forced entry and severe weather deteriorates
Solution Approach 1:
The connector assembly is segmented into multiple functional components including mounting brackets, support arms, and fastening mechanisms distributed at multiple locations. This segmentation allows each component to perform a specific function, enhancing overall reliability and resistance to forced entry while maintaining manufacturability through modular assembly.
Solution Approach 2:
The connector assembly merges multiple support functions into a single integrated system that provides both structural support and thermal breaking. The combination of mounting brackets, support arms, and thermal break components creates a unified assembly that enhances security and weather resistance without requiring separate corner clip mechanisms.
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 reduces energy transfer by up to 25%, enhances safety by preventing burns and frost-related injuries, and increases resistance to forced entry and severe weather conditions, while also reducing carbon footprint through the use of recycled materials.
Implementation Method 1
a thermal break core (202) disposed between the front metal panel and the back metal panel preventing thermal energy transfer
Data Source
AI summary
A door assembly with the dual support connector has a door panel, a glass pane, a dual support connector assembly, a fixed sealing frame for engaging the dual support connector assembly, a seal-less removable frame for attaching to the attachment (dual support connector assembly) on an opposite side of the fixed sealing frame, and a fastener engaging the dual support connector assembly to the fixed sealing frame. The dual support connector assembly has a clip body, a door flange extending from the clip body, a glass flange extending from the clip body in parallel with the door flange.