Thermally Insulating Composite Frame with Crimped Bridge Isolator
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Solution Overview
Problem
Existing thermally insulating composite frame systems for windows and doors require costly, time-consuming de-bridging operations to separate thermal isolators, and previous solutions like snap-in isolators with complex H-shapes are cumbersome and require additional bonding for shear resistance.
Innovation Solution
A composite frame apparatus with elongated profile members connected by a thermally insulating bridge member, featuring crimpable flange members and a bridge member with head portions and foot members, which allows for a secure, shear-resistant connection without the need for de-bridging or additional bonding, using materials like polyamide for low thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermal isolators are used in composite frame systems, then thermal insulation is provided, but costly and time-consuming de-bridging operations are required to separate the isolators
Solution Approach 1:
The thermal isolator is divided into discrete segments that can be independently formed and assembled. Each segment is a separate component that fits into the frame structure without requiring de-bridging operations, allowing for efficient manufacturing and assembly while maintaining thermal insulation performance
Solution Approach 2:
The thermal isolator is extracted as a separate, removable component from the frame structure. This allows the isolator to be manufactured independently and then assembled into the final product, eliminating the need for costly and time-consuming de-bridging operations while preserving thermal insulation functionality
2Manufacturing precision
If snap-in isolators with H-shaped cross sections are used, then alignment during assembly is improved, but the structure becomes complicated and requires additional bonding for shear resistance
Solution Approach 1:
The isolator structure incorporates localized features such as flanges and engagement surfaces at specific locations to provide alignment and shear resistance. Instead of using a complex H-shaped cross section throughout, the design uses simple geometric forms with strategically placed features that achieve the same functional goals with reduced complexity
Solution Approach 2:
The isolator employs asymmetric flange configurations and engagement surfaces that provide inherent alignment during assembly. The asymmetric design creates natural positioning features that guide the components into correct alignment without requiring complex symmetric H-shaped structures or additional bonding agents
3Reliability
If multiple thermal isolators are used to separate frame members, then thermal insulation is enhanced, but the number of components and assembly complexity increases
Solution Approach 1:
Multiple thermal isolator functions are merged into a single integrated component. The isolator simultaneously provides thermal insulation, alignment, shear resistance, and spacing functions through its unified design, reducing the total number of components while enhancing thermal insulation performance
Solution Approach 2:
The thermal isolator is designed as a multi-functional component that performs multiple roles: thermal insulation, structural spacing, alignment guidance, and shear force resistance. This universal design eliminates the need for separate components for each function, reducing overall system complexity while maintaining enhanced thermal insulation
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 a cost-effective, efficient, and secure thermal insulation with improved shear strength and reduced material costs, eliminating the need for de-bridging and additional bonding, while maintaining a mechanically secure and thermally efficient connection.
Implementation Method 1
a bridge member (16) supporting the first and second profile members (12, 14) in a spaced relationship... made of a material exhibiting low thermal conductivity characteristics
Implementation Method 2
the first and second flange members of the first connection region being selectively crimpable inwardly in a direction along a transverse axis
Data Source
AI summary
A composite frame member includes a pair of profile members extending in a longitudinal direction (Z) and held at connection regions thereof in a parallel, spaced apart relation by an insulating bridge member. The bridge member carries first and second head portions on opposite ends in a height direction (Y) wherein the head portions define outer planar surfaces and first and second inner planar surfaces. The first outer planar surface and the first and second inner planar surfaces of each head portion are mutually parallel and spaced apart in the height direction (Y). Opposed first and second flange members of each connection region are crimped inwardly and abut the outer planar surfaces and generate holding forces F exclusively in the height direction (Y) perpendicular to the longitudinal (Z) and transverse (X) directions.