Composite Profile Clamping Mechanism for Dimensional Stability
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Solution Overview
Problem
Existing composite profiles for windows, doors, and facades face challenges in achieving high dimensional stability and cost-effective production while ensuring a stable connection between metal and insulator profiles to prevent thermal bridges and load-induced deformation.
Innovation Solution
A composite profile design featuring a metal profile with a groove and web structure, where the insulator profile engages in pockets on both sides of the web, providing a clamping effect that enhances dimensional stability without the need for additional cohesive connections between web-forming profile sections, and allowing for simple and inexpensive production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If profile sections of the metal profile are connected by cohesive connections (laser welding, roller welding, soldering or gluing) to prevent groove bending, then the dimensional stability is improved, but the production complexity and cost increase
Solution Approach 1:
The insulator profile itself serves as the clamping element that prevents groove bending. By designing the insulator profile with appropriate geometry and material properties, it automatically provides the necessary clamping force on the web-forming profile sections, eliminating the need for separate cohesive connections between these sections.
Solution Approach 2:
The cohesive connection elements (welding, soldering, gluing) are removed from the system. The patent achieves the same stabilizing function through a different mechanism - the insulator profile directly clamping the web-forming sections, thereby extracting the complex connection processes and replacing them with a simpler mechanical clamping arrangement.
2Strength
If additional cohesive connections are added to prevent groove bending under load, then the structural stability is improved, but the production cost increases
Solution Approach 1:
The insulator profile performs multiple functions simultaneously: it provides thermal insulation, mechanically connects the metal profile sections, and acts as a clamp to prevent groove bending. This multi-functionality eliminates the need for separate structural reinforcement elements, reducing production cost while maintaining structural stability.
Solution Approach 2:
The functions of thermal insulation and structural stabilization are merged into a single component - the insulator profile. By combining these functions, the patent avoids the need for additional stabilization elements that would increase production cost, achieving both thermal performance and structural integrity through one element.
3Manufacturing precision
If the web-forming profile sections are rigidly connected to prevent bending, then the dimensional stability is improved, but the manufacturing simplicity is reduced
Solution Approach 1:
The insulator profile automatically provides the clamping force needed to prevent web separation through its own geometric design and material properties. The profile sections are shaped to interlock with the insulator, creating a self-clamping mechanism that maintains dimensional stability without requiring complex manufacturing processes or additional rigid connections.
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 achieves increased dimensional stability and prevents groove bending under load, ensuring a permanently stable composite profile with improved thermal separation and reduced production costs.
Implementation Method 1
The insulator profile and/or a further profile received in the groove engage in pockets of the metal profile which are open towards the groove and arranged on both sides of the web, via which a web-encompassing clamping is achieved, counteracting a bending open of the groove
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a composite profile for windows, fixed glazing, facades, doors or glass roofs, comprising a metal profile (1) produced from a sheet metal material by forming, in particular by roll forming, which has a profile cross-section forming a groove (2) and a web (3), wherein the web (3) is formed from profile sections (3.1, 3.2) which lie at least partially on top of each other and transition into profile sections (2.1, 2.2) which define the groove (2), further comprising a one-piece or multi-piece insulator profile (4) which is received section by section in the groove (2) of the metal profile (1) and is connected to the metal profile (1) by force and/or form locking. According to the invention, the insulator profile (4) and/or a further profile (5) received in the groove (2) of the metal profile (1) engage in pockets (6) of the metal profile (1) which are open towards the groove (2) and are arranged on both sides of the web (3).The invention further relates to a method for producing a composite profile according to the invention.