Composite Profile Shear-Free Connection for Thermal Warping
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Solution Overview
Problem
Existing composite profiles for doors, windows, and facade elements face issues with bimetallic effects due to thermal expansion, leading to warping and potential leaks, particularly in profiles exposed to sunlight, and existing solutions are complex to produce.
Innovation Solution
A composite profile design featuring two outer profiles connected via an insulating profile with thickened end sections and pressure elements, such as elastomer springs, allowing for torque application to support the insulating profile on undercuts and end faces, creating a shear-retarded bond that accommodates thermal expansion without complex production processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a shear-resistant connection is used between outer profiles and insulating web, then displacement prevention is improved, but bimetallic warping and leaks worsen due to thermal expansion differences
Solution Approach 1:
The connection between outer profiles and insulating web is transformed from a rigid fixed connection to a dynamic connection that allows controlled relative movement. The insulating web can move longitudinally within the outer profiles, enabling the structure to adapt to thermal expansion and contraction while maintaining connection integrity.
Solution Approach 2:
The connection parameters are changed from rigid constraints to flexible constraints. By allowing longitudinal movement while maintaining transverse positioning, the connection accommodates dimensional changes due to thermal expansion, preventing the buildup of stresses that cause warping.
2Reliability
If a shear-free composite design is used to allow longitudinal movement, then bimetallic warping is reduced, but manufacturing complexity increases
Solution Approach 1:
The complex movable connection mechanism is extracted from the composite profile itself and replaced by simple geometric features: grooves in the outer profiles and corresponding end sections with undercuts and end faces on the insulating web. This allows longitudinal movement while maintaining manufacturing simplicity.
Solution Approach 2:
Instead of implementing complex movable joints, the solution uses simplified geometric copies of connection features that achieve the same functional effect through basic shapes and arrangements, reducing manufacturing complexity while maintaining the shear-free capability.
3Strength
If rigid connection between insulating web and outer profiles is used, then structural integrity is improved, but thermal expansion accommodation worsens
Solution Approach 1:
The connection is segmented into different functional zones: the insulating web is positioned transversely by grooves and undercuts for structural integrity, while longitudinal movement is permitted through the shear-free design. This segmentation allows simultaneous achievement of strength and thermal adaptability.
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 design simplifies production and minimizes bimetallic effects by allowing relative displacement between the insulating and outer profiles, reducing the risk of warping and leaks while maintaining structural integrity and thermal insulation.
Implementation Method 1
the different thermal expansion rates of the inner and outer shells of a frame profile create a bimetallic effect
Implementation Method 2
the different thermal expansion rates of the inner and outer shells of a frame profile create a bimetallic effect
Implementation Method 3
at least one pressure element - for example, a simple elastomer spring - is provided, wherein, due to the action of the at least one pressure element, a torque can be exerted
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
A composite profile (4) for doors (1), windows or facade elements with two outer profiles (12, 13) connected to each other via an insulating profile (14) arranged between them, wherein a surface element (42) engages between one end of the outer profiles (12, 13) and wherein an elastic element (18, 28), in particular a seal, is arranged between the outer profiles (12, 13) and the surface element (42), wherein the insulating profile (14) has at least two thickened end sections (35a, b; 36a, b) towards each of the outer profiles (12, 13) which engage in grooves (20, 21; 29, 30) of the respective outer profiles (12, 13), wherein one of the two end sections (35a; 35b) is located closer to the surface element (42) than the other of the end sections (36a; 36b), wherein the final sections (35a and 36a;35b and 36b) each have mutually facing sides forming undercuts (39a, 39b) and mutually facing sides forming end faces (41a), is characterized in that, due to the action of the surface element (42) via the elastic element(s) 18, 28), a torque is exerted on the outer profiles (12, 13) in such a way that the end sections (35a, 35b) of the insulating profile located closer to the surface element (42) are supported only at their mutually facing undercuts (39a, 39b or 40a, 40b) in the respective groove (20; 29) and that the end sections (36a, 36b) located further away from the surface element (42) are each supported with their mutually facing end faces (41a, 41b) in the respective groove (20; 29) are supported, so that a shear-free connection is formed between the insulating profile (14) and the outer profiles (12, 13).;