Unitary Extruded Shell for Rolling Door Slats
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Solution Overview
Problem
Existing rolling door slat designs often fail to effectively insulate the coupling ends, allowing heat transfer, and require complex assembly and multiple components.
Innovation Solution
A unitary extruded shell with arcuate segments forming an articulated hinge allows for the assembly of single or double-walled slats without additional insulation between the shells, using a single profile extrusion to create hingedly joined shells that can be easily assembled and modified for insulation and ballistic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple separate components are used to assemble slats with insulation, then insulation effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent combines the shell structure and insulation material into a single unitary extruded component. The thermally insulating material is integrated within the shell itself, eliminating the need for separate insulation components and complex assembly procedures while maintaining effective thermal insulation at the coupling ends.
Solution Approach 2:
The unitary extruded shell serves multiple functions simultaneously: it provides structural support, thermal insulation, and coupling mechanisms for connecting slats. This multi-functional design eliminates the need for separate dedicated insulation components while reducing overall device complexity.
2Loss of energy
If different materials are used for outer and inner walls with insulation filling, then thermal insulation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the manufacturing of outer and inner walls with insulation into a single extrusion process. The unitary extruded shell is formed in one continuous operation, eliminating the need for separate manufacturing steps for different materials and insulation filling operations.
Solution Approach 2:
The invention changes the material parameter from multiple materials to a single thermally insulating material that provides both structural and insulation functions. This parameter change simplifies the manufacturing process while maintaining thermal insulation effectiveness through the integrated shell design.
3Loss of energy
If complex multi-component assemblies are used, then insulation performance is improved, but ease of operation deteriorates
Solution Approach 1:
The patent combines multiple components into a single unitary extruded shell that requires no separate assembly steps for insulation installation. The integrated design allows for straightforward installation while maintaining effective thermal insulation at the coupling ends.
Solution Approach 2:
The unitary extruded shell is designed to be self-contained with all insulation features built-in during manufacturing. This self-service design eliminates the need for additional assembly operations or specialized installation procedures, improving ease of operation while maintaining insulation performance.
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 effective thermal insulation by preventing heat transfer through the coupling ends and simplifies the assembly process, using a single extrusion to form both insulated and non-insulated slats, while also enhancing ballistic resistance without increasing weight.
Implementation Method 1
said first and second arcuate segments being positioned on the same side of said planar portion and offset from said second surface in said second normal direction and configured and dimensioned to enable said second arcuate segment of a first shell to be received with clearance within a first arcuate segment of a second shell substantially identical to said first shell to form an articulated hinge
Implementation Method 2
the curved engaging ends, which couple or link one slat to the next adjoining slat are covered with a heat insulating material so that there is no heat transfer through the engaging or coupling ends themselves
Data Source
AI summary
An elongate shell for forming a slat for a rolling door includes a planar portion having parallel first and second longitudinal edges and formed along the first longitudinal edge with a first arcuate segment and formed along an opposing second longitudinal edge with second arcuate segment, the first and second arcuate segments being positioned on the same side of said planar portion and configured and dimensioned to enable the second arcuate segment of a first shell to be received with clearance within a first arcuate segment of second shell identical to the first shell to form an articulated joint hingedly connecting the elongate shells so they can be pivoted relative to each other. Two identical shells can be oriented to be assembled to form a double-walled slat with longitudinal hooks or claws for assembling a plurality of slats, with or without insulation, into a curtain assembly for a rolling door.