Fenestration Joint Induction Welding for Strong Seamless Frames
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Solution Overview
Problem
Manufacturing fenestration units, such as doors and windows, is inefficient, costly, and challenging due to the use of fasteners, adhesives, and difficulties in creating aesthetically pleasing and strong joints.
Innovation Solution
The use of induction welding with a weld interface member composed of a susceptor and cover portion, where the susceptor material is susceptible to induction heating, allowing for the fusion of polymeric materials to form strong, aesthetically pleasing joints without the need for fasteners or adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fasteners, adhesives, or sealants are used to join members, then the joint strength and reliability are improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent replaces mechanical fastening systems (screws, bolts, adhesives) with induction welding technology. The weld interface member with susceptor material enables direct fusion bonding of polymeric members through electromagnetic induction heating, eliminating the need for separate fasteners or adhesives and significantly reducing manufacturing steps and time
Solution Approach 2:
The invention utilizes phase transition of the polymeric material during induction welding. The susceptor material generates heat through induction that melts the polymeric members at the joint interface, and subsequent cooling causes re-solidification to form a strong fusion bond, leveraging the melting and solidification phase transitions for joining
2Strength
If traditional joining methods are used, then the joint strength is maintained, but the aesthetic quality of joints deteriorates
Solution Approach 1:
The weld interface member serves as an intermediary component between the two polymeric members to be joined. It provides a controlled fusion interface that creates a clean, seamless joint appearance while maintaining structural strength, eliminating the visible fasteners or adhesive lines associated with traditional joining methods
Solution Approach 2:
The invention applies local quality by concentrating the susceptor material specifically at the joint interface where welding is needed, while the rest of the polymeric members maintain their original aesthetic properties. The weld interface member is designed to be visually minimal or hidden, providing strength locally without compromising overall appearance
3Productivity
If induction welding with weld interface member is used, then manufacturing efficiency and joint quality are improved, but the device complexity increases
Solution Approach 1:
The weld interface member with susceptor material serves multiple functions simultaneously: it acts as a heat generation element through induction, a mold for the joint geometry, a seal for weather resistance, and an aesthetic finish element. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing system despite the advanced welding technology
Solution Approach 2:
The weld interface member is constructed as a composite material system combining polymeric material with embedded susceptor material (such as ferromagnetic particles). This composite structure enables the non-magnetic polymeric members to be joined through induction welding while maintaining the aesthetic and structural properties of the original materials, reducing system complexity by integrating multiple functions into one component
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 method enables efficient manufacturing of fenestration units with robust, weather-resistant, and ergonomically sound joints, reducing manufacturing time and costs while eliminating the need for additional sealants.
Implementation Method 1
heating, by induction heating, the susceptor material to melt the susceptor portion and the cover portion
Implementation Method 2
The induction welding device is configured to induction heat the susceptor material
Implementation Method 3
at least the susceptor portion includes a susceptor material that is susceptible to induction heating
Data Source
AI summary
A method of manufacturing includes providing a first and second member of a fenestration unit, wherein the first and second members are formed at least partly from a polymeric material. The method further includes providing a weld interface member having a susceptor portion and a cover portion, and at least the susceptor portion includes a susceptor material that is susceptible to induction heating. The cover portion includes a cover material. The method further includes positioning the weld interface member against the first member and the second member at a joint arrangement. The method additionally includes heating, by induction heating, the susceptor material to melt the susceptor portion and the cover portion. Also, the method includes re-solidifying the susceptor portion and the cover portion to attach the first member and the second member, including covering the susceptor material at the joint arrangement with a resolidified portion of the cover material.