Composite Window Frame Corner Joint Using Punched Metal Intermediaries
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Solution Overview
Problem
Conventional composite window/door apparatuses face difficulties in connecting frames made of different materials, such as synthetic resin and metal, which are troublesome, time-consuming, and affect the appearance beauty due to the use of heat-sealing methods or adhesive agents, leading to potential loosening and deterioration of the connected areas.
Innovation Solution
A prefabricated structure that allows for easy and secure connection of synthetic resin frames with metal frames by punching and deforming angle and corner pieces to create a strong joint without the need for heat-sealing or adhesive agents, using corner piece paths and angle piece paths to secure compression flanges and joint grooves for sliding connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat-sealing methods or adhesive agents are used to connect frames made of different materials, then the connection strength is improved, but the appearance beauty deteriorates and the assembly process becomes troublesome and time-consuming
Solution Approach 1:
The frame connection system is segmented into multiple functional components: corner pieces for joining frames, angle pieces for reinforcement, compression flanges for securing, and joint grooves for alignment. This segmentation allows each component to perform its specific function efficiently without requiring complex heat-sealing or adhesive processes.
Solution Approach 2:
Corner pieces and angle pieces act as intermediary elements that facilitate the connection between adjacent frames made of different materials. These intermediaries provide a standardized interface that simplifies assembly while maintaining connection strength, eliminating the need for direct material-to-material joining methods like heat-sealing.
2Strength
If heat-sealing methods or adhesive agents are used to connect frames, then the connection strength is improved, but the appearance beauty deteriorates due to unsightly adhesive areas
Solution Approach 1:
The connection mechanism is extracted from the visible surface area of the frames. Corner pieces and angle pieces are designed to be positioned at joints and corners where they connect frames, while compression flanges secure the connection internally. This extraction ensures that no unsightly adhesive or heat-sealing marks appear on the visible surfaces, maintaining appearance beauty while achieving strong connections.
3Ease of manufacture
If conventional connection methods are used to join synthetic resin frames and metal frames, then the connection is achieved, but the assembly becomes troublesome and time-consuming
Solution Approach 1:
Corner pieces and angle pieces are pre-formed with specific geometries including receiving grooves and punched-deformed parts. The frames are also pre-equipped with compression flanges and joint grooves. This preliminary preparation allows for rapid assembly through simple punching and deformation operations without requiring time-consuming heat-sealing or adhesive application and curing processes.
Solution Approach 2:
The connection method replaces thermal (heat-sealing) and chemical (adhesive) systems with a purely mechanical system. Corner pieces and angle pieces are connected to frames through punching and deformation, creating secure mechanical joints. This mechanical substitution dramatically reduces assembly time and simplifies the manufacturing process while maintaining connection strength.
4Ease of manufacture
If the frames are connected using adhesive agents, then the connection is achieved, but the connected areas may loosen and deteriorate over time
Solution Approach 1:
The connection system is self-securing through mechanical interlocking. Corner pieces and angle pieces with punched-deformed parts automatically lock into receiving grooves when assembled, and compression flanges apply continuous pressure to maintain the connection. This self-service mechanism eliminates reliance on adhesives that can degrade over time, ensuring long-term reliability without requiring additional maintenance.
Data Source
AI summary
A prefabricated structure for a composite window apparatus using different frame materials.The sides of the corners of adjacent first window frames and adjacent first sash frame which made of synthetic resin are punched, the punched parts of the first window frames, the punched parts of the first sash frames and the parts of the angle pieces are bent inwardly. When the punched parts of the angle piece are bent into the corner piece, the window frame compression flanges of the first window frames are pressurized by the angle piece and the corner piece, and the sash frame compression flanges of the first sash frames are pressurized by the angle piece and the corner piece, so that the corners of the first window frames and the corners the first sash frames are connected to respective angle pieces and corner pieces.