Composite Profile Welded Foamed Core Sheath
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Solution Overview
Problem
Composite profiles face weaknesses at material transitions due to stress, particularly in windows and doors, which compromise thermal and acoustic insulation, and existing solutions fail to adequately strengthen these connections.
Innovation Solution
A composite profile design with a foamed core made of a first plastic and a sheath of a second plastic, both compatible and welded together, forming a material-to-material bond without adhesives, and incorporating projections for positive connections to enhance strength and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If insulating bars are installed in the frame to improve thermal insulation, then thermal insulation properties are improved, but the connection strength between inner and outer shells deteriorates due to stress concentration at material transitions
Solution Approach 1:
The patent applies composite materials by combining a foamed core made of a first plastic with a sheath made of a second plastic. This composite structure allows the foamed core to provide thermal insulation while the sheath provides structural strength and stress distribution, resolving the contradiction between thermal insulation and connection strength at material transitions
Solution Approach 2:
The patent applies local quality by creating a material-to-material bond between the foamed core and sheath through welding at the transition zones. This localized strengthening at the connection points allows the insulating bars to maintain thermal insulation performance while preventing failure at the vulnerable material transition areas
2Strength
If adhesive bonding is used to connect materials in composite profiles, then connection strength is improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent replaces the chemical bonding mechanism of adhesives with a thermal welding process. The sheath is welded to the foamed core through heat application, creating a strong material-to-material bond without requiring adhesive applications, clamping systems, or complex assembly fixtures, thereby simplifying the manufacturing process
Solution Approach 2:
The patent merges the core and sheath into a single integrated composite profile through welding. This combining of components into one unified structure eliminates the need for separate bonding operations and reduces manufacturing steps, achieving both strong connection and process simplification
3Loss of energy
If thicker insulating bars are used to improve insulation, then thermal and sound insulation are improved, but the profile weight and material consumption increase
Solution Approach 1:
The patent uses composite materials with a foamed core that provides high thermal and sound insulation per unit volume. The foam structure achieves superior insulation performance without requiring increased thickness, thereby maintaining lower weight and material consumption while meeting insulation requirements
Solution Approach 2:
The patent changes the density parameter of the insulating material by using foamed plastic with controlled cell structure. This parameter change allows achieving high insulation performance with reduced material density and thickness, thereby reducing overall profile weight while maintaining or improving thermal and sound insulation properties
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 design significantly increases strength and insulation properties, allowing for higher load resistance and improved thermal and sound insulation by optimizing material usage and minimizing heat flow.
Implementation Method 1
The first and second plastics are compatible with one another, so that they form a material-to-material bond
Data Source
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AI summary
The invention relates to a composite profile with a foamed core made from a first plastic and an envelope enclosing the core made from a second plastic, which envelopes the core in an interlocking manner. According to the invention, the first and the second plastic are compatible with one another, that is to say can form an integrally bonded connection with one another.