Curved Fenestration Assemblies Using Composite Segments
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Solution Overview
Problem
Fenestration manufacturers face challenges in producing fenestration assemblies with specified curvatures without collapsing lineal segments, leading to increased damage and inventory depletion, due to the deformation of hollow profiles during bending and the difficulty in using deformable rods for restoration.
Innovation Solution
The use of composite lineal segments, assembled at the joint before deformation, with a navigated curving assembly and guide profiles to impart curvature collectively, and the inclusion of foam or polymer braces to support segment walls and prevent collapse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If lineal segments with hollow profiles are heated and deformed in bending machines to achieve specified curvatures, then the desired curved shape is obtained, but the walls surrounding the cavities collapse into the cavities causing damage to the lineal segments
Solution Approach 1:
The patent applies preliminary action by inserting expandable props into the cavities of the hollow profile lineal segments before the heating and bending process. These props are expanded during deformation to internally support the cavity walls, preventing them from collapsing into the cavities during the curving process. This preliminary preparation ensures structural integrity throughout the forming operation.
2Adaptability or versatility
If multiple permutations of lineal members with various colors, finishes, profiles, and constructions are maintained in warehouse or production facilities, then customer specifications can be met, but substantial outlay for inventory maintenance and production facilities is required
Solution Approach 1:
The patent applies segmentation by dividing the lineal member into multiple separable segments that can be independently manufactured and stored. Instead of maintaining complete assembled fenestration assemblies in various permutations, manufacturers can store individual segments (frames, sashes, dividers) separately and assemble them as needed. This dramatically reduces inventory requirements while maintaining the ability to produce diverse product configurations.
3Manufacturing precision
If deformable rods are navigated into cavities to force open deformed walls during bending, then restoration of the profile hollows is attempted, but additional damage to lineal segments occurs and inventories are drained
Solution Approach 1:
The patent applies preliminary action by pre-installing expandable props into the cavities before bending occurs. When deformation happens, these props automatically expand to prevent wall collapse, eliminating the need for subsequent restoration attempts with deformable rods. This preventive approach avoids the additional damage that would result from navigating rods into already-damaged cavities and attempting to force walls open.
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 approach reduces the risk of segment damage and collapse, minimizes the need for repeated production, and allows for the efficient production of fenestration assemblies with complex curvatures, while reducing storage and production costs by allowing for the mixing and matching of component segments with different characteristics.
Implementation Method 1
The foam or polymer braces support the segment walls and prevent collapse
Implementation Method 2
deforming the composite lineal segment to the specified curvature according to the one or more guide profiles
Data Source
AI summary
A fenestration assembly includes a plurality of lineal segments joined at corners. Each of the lineal segments extend between first and second ends. One or more of the lineal segments of the plurality of lineal segments is a composite lineal segment and includes a first component lineal segment and a second component lineal segment. The first and second component lineal segments are coupled at an assembly joint in an assembled configuration.