Thermally Separated Aluminum Window Profiles with Plastic Barriers

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Solution Overview

Problem

Existing window and door systems with thermally separated aluminum hollow chamber profiles suffer from thermal bridges, leading to condensation on the inside glass pane due to cold penetration through hollow chamber profiles, particularly in the partially flush closed position.

Innovation Solution

The use of an outer casement frame with an aluminum profile forming the outer wall and an inwardly directed plastic chamber profile for thermal separation, combined with a labyrinth seal and web connections for static support and sealing, prevents heat and cold transfer across the glass surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If aluminum hollow chamber profiles are used for the outer casement frame, then structural strength and aesthetic appearance are improved, but thermal bridges form allowing cold penetration and condensation

Engineering Contradiction:

Improvestructural strengthVSAvoidthermal bridge causing condensation

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining aluminum profiles with plastic thermal separation elements within the same hollow chamber profile structure. The aluminum provides structural strength and aesthetic appearance, while the plastic inserts create thermal barriers that prevent cold bridges, thus resolving the contradiction between strength and thermal insulation.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The hollow chamber profile is segmented into multiple functional zones: aluminum structural walls for strength, plastic thermal separation elements for insulation, and sealed compartments for thermal performance. This segmentation allows each material to perform its optimal function without compromising the others.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the inner sash frame is arranged flush on the outer sash frame in closed position, then sealing effectiveness is improved, but thermal bridges form at the frame interface

Engineering Contradiction:

Improvesealing effectivenessVSAvoidthermal bridge at frame interface

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces plastic thermal separation elements as intermediary components between the inner and outer sash frames. These elements act as mediators that maintain the flush arrangement for sealing while simultaneously blocking thermal bridges at the frame interface through their insulating properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The frame interface combines aluminum structural components with plastic thermal separation materials, creating a composite construction that achieves both mechanical connection for sealing and thermal insulation to prevent cold bridges.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If thermally separated profiles are used, then condensation is prevented, but device complexity increases with multiple profile types

Engineering Contradiction:

Improvecondensation preventionVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent merges multiple functions into a single hollow chamber profile structure: aluminum structural walls, plastic thermal separation elements, sealed compartments, and mounting features are all integrated into one profile type. This reduces device complexity by eliminating the need for separate assembly of multiple different profile types while maintaining condensation prevention.

Inventive Principle:

Principle #5Merging (Combining)

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 design eliminates thermal bridges, preventing condensation and ensuring effective thermal insulation by maintaining a temperature barrier between the glass and the outward-facing side, while maintaining the aesthetic and structural integrity of an aluminum profile appearance.

Implementation Method 1

an inwardly directed plastic chamber profile (11) for carrying the static load for the casement (6) and for forming a thermal separation between the side (12) bordering the glass pane (4) and the side (12) running transversely to the glass surface of the first casement (5) outward-facing side (13)

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

A sealing profile (7) is also arranged on the outwardly pointing half-shell (30), the labyrinth seal (9) being arranged between the sealing profiles of the two casement frames (5 and 6)

Methodology Applied

Scientific EffectLabyrinth seal:

Data Source

PatentEP2489821B1Window and/or door leaf element comprising thermally separate aluminium hollow chamber profiles with enclosed glass panes

Publication Date: 2015.07.29 HEROAL JOHANN HENKENJOHANN GMBH & CO KG

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AI summary

The element (1) has a hollow chamber profile (3) that is provided with an outside pointing window casement frame (6). An aluminum profile is formed on an outer wall of the hollow chamber profile. A plastic chamber profile is arranged inward to form a thermal barrier between a glass enclosed side and another window casement frame (5) that runs transverse to a glass surface on an outer-facing side of the window casement frame.