Coextruded Jacketed Foam Polymer Frames for Insulation and Fastening

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Solution Overview

Problem

Fenestration assemblies made of wood, polymer, or metal face issues such as moisture damage, structural integrity loss, thermal conductivity, and difficulty in fastening due to hollow profiles, leading to maintenance challenges and deformation.

Innovation Solution

The use of jacketed foam polymer members, comprising a foam polymer core enclosed by a polymer shell, which enhances mechanical strength, thermal stability, and provides a solid substrate for fastening, reducing moisture penetration and convective heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If hollow polymer components are used for fenestration assemblies, then thermal insulation is improved and maintenance is reduced, but structural integrity is lost and fastening becomes difficult

Engineering Contradiction:

Improvethermal insulationVSAvoidstructural integrity

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The patent applies composite materials by combining hollow polymer components with wooden inserts or metal reinforcement members. The wooden inserts are positioned within the hollow polymer structure to create a composite assembly that leverages the thermal insulation properties of the polymer while gaining the structural strength and fastening capabilities of wood. This composite approach resolves the contradiction by integrating materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If wood is used for fenestration assemblies, then ease of cutting and fastening is improved, but moisture resistance is worsened

Engineering Contradiction:

Improveease of cutting and fasteningVSAvoidmoisture damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses hollow polymer components as intermediary elements between the wooden structural inserts and the external environment. The polymer acts as a protective barrier that shields the wood from moisture exposure while allowing the wood to provide structural strength and fastening surfaces. This intermediary approach enables the wood to be used for manufacturing purposes without direct exposure to harmful moisture conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If polymer fenestration assemblies are made darker, then aesthetic versatility is improved, but heat absorption increases causing deformation

Engineering Contradiction:

Improveaesthetic versatilityVSAvoidheat absorption

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The patent applies local quality by using lighter-colored polymer materials for the exterior portions of fenestration assemblies that are exposed to sunlight and heat. This localized application of light-colored material reduces heat absorption in critical areas while still allowing for aesthetic customization through other means such as trim colors or interior finishes. The structural wooden inserts can also be treated or finished to provide color variation without the same heat absorption concerns.

Inventive Principle:

Principle #3Local quality

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 jacketed foam polymer members offer improved structural integrity, reduced maintenance, enhanced thermal performance, and robust fastening capabilities, allowing for larger and more durable fenestration assemblies.

Implementation Method 1

a polymer shell jacketing the foam polymer core and coextruded with the foam polymer core, wherein the polymer shell braces the foam polymer core against deformation

Methodology Applied

Scientific EffectMechanical support and bracing:

Implementation Method 2

enhanced thermal performance

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

reducing moisture penetration and convective heat transfer

Methodology Applied

Scientific EffectReduced convective heat transfer: Convection

Implementation Method 4

coextruded foam polymer member having: a foam polymer core; a polymer shell jacketing the foam polymer core and coextruded with the foam polymer core

Methodology Applied

Scientific EffectCoextrusion: Extrusion

Data Source

PatentUS20250256448A1Jacketed foam polymer members, fenestration assemblies, and methods for same

Publication Date: 2025.08.14 MARVIN COMPOSITES LLC

AI summary

A fenestration assembly includes a fenestration frame includes one or more frame members. The fenestration frame is coupled with one or more panels. Each frame member includes a coextruded foam polymer frame member. The coextruded foam polymer frame member includes a foam polymer core and a polymer shell jacketing the foam polymer core. The polymer shell is coextruded with the foam polymer core. The polymer shell braces the foam polymer core against deformation.