3D-Printed Window Frames With Integrated Thermal Break Lattices
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Solution Overview
Problem
Traditional manufacturing methods for windows and doors, such as those using aluminum extrusions with thermal breaks, require numerous steps and expensive equipment, resulting in inefficiencies and high costs.
Innovation Solution
The use of additive manufacturing techniques, including 3D printing, selective laser sintering, and selective laser melting, to create architectural products with composite constructions that vary in material composition, density, and distribution, allowing for reduced production times and elimination of waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods (pour-and-debridge or crimped polyamide) are used for aluminum extrusions with thermal breaks, then thermal insulation performance is achieved, but manufacturing complexity and production time increase significantly
Solution Approach 1:
The patent combines the frame structure and thermal break into a single monolithic component manufactured by additive manufacturing, eliminating the need for separate thermal break inserts and multiple assembly steps. The thermal insulation functionality is integrated directly into the printed lattice structure rather than being added as a separate component.
Solution Approach 2:
The patent changes the manufacturing method from traditional subtractive or assembly-based processes to additive manufacturing, fundamentally altering how the thermal break is created. The lattice structure parameters (cell size, wall thickness, orientation) are optimized to achieve thermal insulation while maintaining structural integrity in a single manufacturing process.
2Reliability
If traditional manufacturing methods with multiple operations are used, then thermal break functionality is achieved, but production time and manufacturing cost increase
Solution Approach 1:
The thermal break structure is pre-designed and pre-manufactured as an integrated lattice pattern within the frame itself during the additive manufacturing process, eliminating the need for subsequent assembly operations. The lattice geometry is predetermined to provide thermal insulation while being created in a single continuous manufacturing process.
Solution Approach 2:
The patent extracts the thermal break functionality from separate components and integrates it directly into the frame structure through additive manufacturing. The lattice pattern is built as an inherent part of the frame rather than being added as a separate insert, reducing the number of manufacturing operations required.
3Loss of substance
If additive manufacturing with lattice structures is used, then material waste is reduced and production efficiency improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs a lattice structure with controlled porosity to achieve thermal insulation while using minimal material. The porous lattice geometry provides thermal break functionality through its air-filled cells while maintaining structural strength, allowing efficient material utilization with reduced waste.
Solution Approach 2:
The lattice structure features varying local densities and cell sizes optimized for different functional requirements. Areas requiring higher strength have denser lattice patterns, while areas prioritizing thermal insulation have more open structures, allowing precise control of properties throughout the component without excessive material usage.
4Ease of operation
If monolithic additive manufacturing is used for window frames, then assembly efficiency improves and parts count reduces, but design flexibility and customization options may be limited
Solution Approach 1:
The additive manufacturing process enables dynamic design optimization where the lattice structure parameters can be varied continuously throughout the component based on functional requirements. The monolithic structure can incorporate varying cell sizes, orientations, and material densities to optimize both assembly efficiency and design flexibility simultaneously.
Solution Approach 2:
The monolithic lattice-structured frame performs multiple functions simultaneously: structural support, thermal insulation, and aesthetic appearance. The integrated design eliminates the need for separate components while maintaining all necessary functionalities, improving assembly efficiency without sacrificing design versatility.
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
This approach enables the production of high-performance windows with reduced lead times, decreased material waste, and improved assembly efficiency, while allowing for customization and flexibility in design and thermal insulation.
Implementation Method 1
an additive manufacturing system that deposits material in a layer by layer fashion to form the architectural manufacture
Implementation Method 2
selective laser sintering
Implementation Method 3
selective laser melting
Data Source
Figure 1A~1B
Figure 2~3
Figure 4
AI summary
An apparatus, method and manufacture utilizes additive manufacturing techniques to produce architectural manufactures such as windows and doors. The manufactures may have a composite construction and may feature inclusions like metal plates and reinforcements. The model used for controlling the manufacturing process may be derived from digital scanning of the structure on which the manufacture is used. Optionally, a finite element analysis is used to test the model and alter it in response to stress and/or thermal requirements.