Thermally Insulated Gate Segments for High-Load Stability
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Solution Overview
Problem
Existing door systems, particularly horizontally opening gates like sliding and folding gates, face challenges in achieving sufficient thermal insulation while maintaining structural stability, especially when subjected to high loads during opening and closing, limiting their size and frequency of use.
Innovation Solution
A door segment design featuring a single-piece profile frame with thermal insulation applied on one or both outer surfaces, where hinges and other load-bearing parts are directly attached, ensuring the insulation extends continuously around the frame circumference, except at hinge locations, enhancing stability and insulation without compromising structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two metal profile halves are connected via a thermal break to achieve thermal insulation, then the thermal insulation of the frame construction is improved, but the structural strength and stability of the gate leaf deteriorate under high loads
Solution Approach 1:
The gate frame is segmented into multiple functional layers: an outer metal profile for structural strength, an intermediate thermal insulation layer for thermal insulation, and an inner metal profile for additional strength. This segmentation allows each layer to perform its primary function independently while working together as a unified structure.
Solution Approach 2:
The frame construction uses a composite structure combining metal profiles with thermal insulation material (such as polyamide or foam). The metal provides mechanical strength while the insulation material provides thermal resistance, creating a composite that achieves both structural and thermal performance requirements simultaneously.
2Temperature
If a thermal break construction is used to improve thermal insulation, then the thermal insulation value is improved, but the manufacturing complexity and effort increase
Solution Approach 1:
The thermal insulation layer is integrated directly into the profile structure during manufacturing, merging the insulation function with the frame construction. This eliminates the need for separate assembly steps to attach thermal breaks, reducing manufacturing complexity while maintaining insulation performance.
Solution Approach 2:
The multi-layer profile design serves multiple functions simultaneously: the outer and inner metal profiles provide structural support and mounting surfaces, while the intermediate layer provides thermal insulation. This multi-functionality reduces the need for additional components and simplifies the overall manufacturing process.
3Ease of operation
If hinges are attached alternately on the outside and inside of a thermally separated frame structure, then the gate can be assembled, but the force flow under load passes through the thermal break, reducing gate leaf strength
Solution Approach 1:
The hinge attachment areas are designed with local reinforcement features directly on the metal profiles, concentrating the load-bearing capacity at specific locations where hinges are mounted. This local quality enhancement ensures that force flows through the strong metal profile sections rather than through the thermal break materials.
4Ease of manufacture
If the frame construction is designed without thermal insulation to simplify manufacturing, then the manufacturing complexity is reduced, but the thermal insulation performance of the door system deteriorates
Solution Approach 1:
The thermal insulation layer is pre-integrated into the profile structure during the manufacturing process rather than being added as a separate post-assembly component. This preliminary action ensures thermal insulation is built-in from the start, maintaining insulation performance while keeping the manufacturing process streamlined.
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 improved thermal insulation comparable to prior art methods while significantly increasing structural stability, allowing for larger and more frequently used gate systems with reduced manufacturing complexity and cost.
Implementation Method 1
the insulation, with the exception of the hinge elements, extends essentially in a closed manner over the circumference of the profile frame
Data Source
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AI summary
A gate segment (10) for forming a single or multi-part gate (100) has a profile frame (20) which defines a segment plane (E) and is fitted with at least one panel (25, 29), wherein the profile frame (20) is provided with thermal insulation (30) on at least one outer surface (21, 23) of the gate segment (10) with respect to the segment plane (E).