EPS Core Window Frame with Polyurethane Shell Insulation
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Solution Overview
Problem
Traditional window frames, including those with polyurethane shells and wooden or PVC cores, fail to meet stringent modern building insulation requirements and are costly, necessitating the development of a more affordable and effective thermal insulation solution.
Innovation Solution
A frame structure utilizing expanded polystyrene (EPS) cores with densities between 80-200 kg/m³, stabilized by polyurethane, which also serves as a glue, and optionally enhanced with high-temperature EPS and additives for improved resistance to compression and melting, combined with a polyurethane shell for enhanced insulation and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If traditional wooden cores are used in PUR frames, then aesthetic appearance is improved, but robustness and insulating properties deteriorate when exposed to moisture
Solution Approach 1:
The patent uses composite materials by combining wood core with PUR shell, where the wood provides aesthetic appearance and the PUR provides robustness and insulation. This resolves the contradiction by integrating the advantages of both materials in a single structure.
2Strength
If PVC cores are used in window frames, then robustness is improved, but insulating properties and aesthetic appeal deteriorate
Solution Approach 1:
The patent employs composite materials with wood core and PUR shell, where the wood core provides better insulating properties compared to PVC, while the PUR shell maintains robustness. This combination resolves the contradiction between robustness and insulation.
3Loss of energy
If PUR shell thickness is increased to improve insulation, then thermal insulating properties are improved, but manufacturing cost and material usage increase
Solution Approach 1:
The patent uses composite materials with wood core and PUR shell, where the wood core contributes to thermal insulation, allowing for reduced PUR shell thickness while maintaining overall insulating performance. This resolves the contradiction between insulation and material usage.
4Stability of the object's composition
If EPS density is increased to improve structural stability, then resistance to compression and melting is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by optimizing EPS density within a specific range (80-200 kg/m³) to achieve the required structural stability and resistance to compression and melting while controlling manufacturing costs. This resolves the contradiction between stability and cost.
5Quantity of substance
If EPS core is used to reduce cost, then manufacturing cost is reduced, but thermal insulation performance deteriorates compared to traditional materials
Solution Approach 1:
The patent uses composite materials with EPS core and PUR shell, where the EPS provides cost-effectiveness and the PUR shell enhances thermal insulation performance. This combination resolves the contradiction between cost and insulation performance.
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 EPS core with polyurethane shell provides a cost-effective, thermally insulating, and robust window frame structure that meets stricter building regulations, balancing insulation properties and economic viability, with the option of varying densities and incorporating reinforcing materials for added strength.
Implementation Method 1
a frame structure, such as a window sash or a frame for a window or door, including side, top and bottom pieces, said frame structure comprising a core made from at least one core member and a shell of polyurethane encasing the core
Implementation Method 2
at least one core member is made from expanded polystyrene (EPS) with a density of 80-200 kg/m³
Data Source
Figure 1
Figure 2~3
Figure 4A~4K
AI summary
The invention relates to a frame structure, such as a window sash or a frame for a window or door, comprising a core made from at least one core member made from expanded polystyrene (EPS) with a density of 80-200 kg/m3 and a shell of polyurethane (PUR) encasing the core. At least one joint between core members and/or core pieces of the frame structure is stabilized by polyurethane material having been allowed to flow into the gaps between the core members and/or core pieces, where it has sets, thus functioning as a glue. The core may include a plurality of core members, some of which may be made from a different material.