Co-extruded Window Profile with Laminated Metal Layer
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Solution Overview
Problem
The production and installation of window and door frames with aluminum screens are time-consuming due to the need for cutting, milling, and mounting, as well as requiring special glazing seals for tightness, which complicates the manufacturing process.
Innovation Solution
A profile with a thin metal layer, such as copper or aluminum, is laminated onto the extrusion profile using an adhesive, allowing for a more efficient and space-saving production process, where the metal layer can be easily adapted to irregular surfaces and integrated into the extrusion process, eliminating the need for precise dimensioning and separate glazing seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an aluminum frame screen is clipped onto a plastic frame to provide UV tolerance and metallic appearance, then UV tolerance and heat insulation are improved, but production time and installation complexity increase significantly
Solution Approach 1:
The patent combines the plastic frame and metal layer into a single integrated component produced through co-extrusion. The metal layer (aluminum, stainless steel, or other metals) is extruded together with the plastic material to form a unified profile, eliminating the need for separate clipping operations and reducing production time while maintaining UV protection and metallic appearance
Solution Approach 2:
The co-extruded profile serves multiple functions simultaneously: it provides structural support, UV protection, thermal insulation, and aesthetic appearance in a single component. The metal layer contributes to both protective functions (UV tolerance, strength) and aesthetic function (metallic look) while being integrated into the manufacturing process
2Object-affected harmful factors
If an aluminum frame screen is clipped onto a plastic frame to provide UV tolerance and metallic appearance, then UV tolerance and heat insulation are improved, but device complexity increases due to additional seals and mounting requirements
Solution Approach 1:
The patent merges the frame structure and protective/metallic layers into a single co-extruded component. The metal layer is integrated during extrusion, eliminating the need for separate mounting hardware, seals, and assembly steps, thereby reducing installation complexity while maintaining UV protection and aesthetic appearance
3Object-affected harmful factors
If a thick aluminum frame screen (1.2-3 mm) is used to provide structural support and UV protection, then UV tolerance and strength are improved, but weight and material consumption increase
Solution Approach 1:
The patent applies a thin metal layer (0.05-0.5 mm) only where needed for UV protection and aesthetic appearance, rather than using thick aluminum throughout. The metal layer is applied as a surface coating or thin laminate on the plastic frame, providing sufficient UV tolerance while dramatically reducing material consumption compared to solid thick aluminum frames
Solution Approach 2:
The patent uses composite construction combining plastic and metal in a co-extruded profile. The plastic base provides structural support and insulation, while the thin metal layer provides UV protection and aesthetic appearance. This composite approach reduces overall material consumption compared to solid thick aluminum while maintaining protective and aesthetic functions
4Productivity
If a thin metal layer is laminated onto the profile instead of using a thick aluminum screen, then productivity is improved and production time is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent combines the metal layer application with the extrusion process itself through co-extrusion. Both the plastic and metal layers are formed and bonded together in a single continuous extrusion operation, eliminating the need for separate lamination steps. This integrated approach maintains high productivity while reducing precision requirements compared to post-extrusion lamination methods
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 method simplifies the production of window and door frames by reducing production time and eliminating the need for complex installation processes, while providing enhanced UV tolerance and radiant heat insulation.
Implementation Method 1
a metal layer (5), in particular a metal foil, which is laminated by means of an adhesive at least partially onto an outer side of the profile (1)
Data Source
AI summary
A profile (e.g. an extrusion profile such as a monoextrusion or co-extrusion profile), for a door and/or window part may include a metal layer of less than 1.0 mm thickness laminated at least partially to an outer side of the profile using an adhesive.