Composite Profile Inner Reinforcement for Window Frames
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Solution Overview
Problem
Pure plastic hollow profiles, such as those made of PVC, lack sufficient strength and flexural rigidity, especially when heated, and existing reinforcement methods like metal inserts are prone to corrosion and complicate manufacturing, while aluminum facings are expensive and thermally unfavorable.
Innovation Solution
A composite profile with an inner reinforcement of impact-reinforced plastic attached to the inside of the plastic hollow profile, which is not visible from the outside, and an optional outer reinforcement, allowing for high static load capacity without visible aluminum or steel on the room side, while maintaining thermal insulation and optical advantages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal reinforcements (steel or aluminum) are used to increase strength and stiffness, then load-bearing capacity is improved, but thermal conductivity increases and corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining plastic hollow profiles with aggregate-reinforced plastic inner reinforcements. The aggregate-reinforced plastic (containing mineral aggregates like glass beads, limestone, or marble) provides enhanced strength and stiffness comparable to metal reinforcements, while maintaining the thermal insulation and corrosion resistance properties of plastic materials.
2Strength
If aluminum cladding is applied on both sides to ensure structural stability, then strength is improved, but cost increases and thermal insulation deteriorates
Solution Approach 1:
The patent applies local quality by placing aggregate-reinforced plastic inner reinforcements only where structurally necessary (in the hollow chambers of the profile) rather than applying aluminum cladding uniformly on both sides. This localized reinforcement approach achieves the required structural stability while minimizing material usage and preserving thermal insulation properties.
3Strength
If insertable metal reinforcements are used, then strength is improved, but manufacturing complexity increases due to corrosion protection and welding difficulties
Solution Approach 1:
The patent applies parameter changes by transitioning from metal reinforcements to aggregate-reinforced plastic reinforcements, fundamentally changing the material parameter. This eliminates the need for corrosion protection coatings and enables standard plastic welding processes to be used, thereby simplifying the manufacturing process while maintaining strength improvements.
4Object-affected harmful factors
If pure plastic hollow profiles are used, then thermal insulation and appearance are maintained, but strength and flexural stiffness are insufficient
Solution Approach 1:
The patent resolves this contradiction by creating a composite structure where the outer plastic hollow profile maintains thermal insulation and aesthetic properties, while the inner aggregate-reinforced plastic reinforcement provides the necessary strength and flexural stiffness. The two materials work together synergistically to satisfy all requirements.
Data Source
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Figure 2a
AI summary
The invention relates to a composite profile (100) for manufacturing frames for windows or doors, comprising a hollow plastic profile (10), in particular made of polyvinyl chloride, with several hollow chambers (60), wherein an outer wall reinforcement (30), preferably made of metal, in particular aluminum, is attached to the outside of the outer wall (20) of the hollow plastic profile (10), in particular the outer wall (20) that is exposed to the elements during intended use, in particular by bonding in a shear-resistant manner, preferably on/in a fastening groove (21) of the outer wall (20), wherein at least one inner reinforcement (50) is provided on the inner side of the inner wall (40) facing the interior of the profile and/or on an inner web (41) of the hollow plastic profile (10) that is spaced parallel to the inner wall, in particular the inner wall (40) that faces the interior of a building during intended use.Preferably exactly one single inner reinforcement (50) made of an aggregate-reinforced plastic is bonded together, preferably by co-extrusion. The invention also relates to a frame for a window or a door.