Composite Profile Miter Joint via Protruding Core Welding
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Solution Overview
Problem
Existing methods for creating miter joints in composite profiles, particularly those combining heat-weldable and non-heat-weldable materials, are cumbersome, costly, and lack assurance of strong and watertight connections.
Innovation Solution
A composite profile design featuring a polymeric core and a side profile with specific coupling means that allow the side profile to be repositioned, enabling a fool-proof miter joint creation through welding of protruding sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-made inserts are introduced into composite profiles to enable miter joint welding, then welding reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the heat-weldable material from the composite profile by cutting it to protrude beyond the non-weldable material ends. This allows the weldable material to be used for joining while the non-weldable material remains exposed for aesthetic purposes, eliminating the need for custom inserts and complex assembly processes.
Solution Approach 2:
Instead of adding inserts to provide weldable material, the invention inverts the approach by removing excess non-weldable material and using the existing weldable material core to protrude beyond the cut end. This reversal simplifies the assembly process while maintaining welding reliability.
2Reliability
If PVC zones are debited in excess to allow welding consumption, then welding is enabled, but additional recovery operations are required
Solution Approach 1:
The invention performs preliminary action by pre-cutting the composite profiles at 45° angles with the weldable material protruding beyond the non-weldable material ends. This preparation enables direct welding without requiring additional recovery operations, improving assembly efficiency while maintaining welding capability.
3Ease of manufacture
If mechanical connection is used for non-weldable materials like aluminum, then assembly is simplified, but connection strength and tightness are reduced
Solution Approach 1:
The invention uses composite materials by combining weldable PVC and non-weldable aluminum in a single composite profile. The weldable PVC core protrudes to enable strong welding joints, while the non-weldable aluminum remains exposed for aesthetic purposes. This composite structure allows the profile to be worked as if it were homogeneous material during machining while maintaining the benefits of both materials.
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 solution ensures a strong, reliable, and watertight miter joint without the need for custom-made inserts or complex assembly processes, thereby simplifying the assembly of window or door frames.
Implementation Method 1
welding together two facing protruding sections of the composite profiles to create the miter joint
Data Source
AI summary
A composite profile includes a polymeric core and a side profile configured to be provided on an external surface of the core profile. The composite profile has a longitudinal direction Y, a depth direction X perpendicular to the Y-direction and a height direction Z, perpendicular to the X and Y directions. The polymeric core profile and the side profile include a first set of coupling means for attaching the side profile in a first position on the polymeric core profile and a second set of coupling means for attaching the side profile in a second position on the polymeric core profile. The side profile is repositioned over a distance D in the Z-direction when coupling the side profile and polymeric core profile with the second set of coupling means versus a coupling with the first set of coupling means.