Fenestration Thermal Break Assembly With Crimped Tab Interlock
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Solution Overview
Problem
Existing fenestration systems face challenges in balancing aesthetic design with energy efficiency, particularly in metal-framed structures where thermal conductivity is high, necessitating improved thermal separation methods.
Innovation Solution
A thermal break profile with a continuous tab design that temporarily secures to profile extrusions via crimping, enhancing mechanical interlock and structural strength, allowing pre-assembly before crimping, and utilizing materials with lower thermal conductivity to minimize heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal frames are used for fenestration systems, then structural strength and aesthetic design are improved, but thermal conductivity increases leading to poor energy efficiency
Solution Approach 1:
A thermal break component made of low thermal conductivity material is introduced as an intermediary element between the interior and exterior metal frame members. This thermal break includes a body with a first end received in the interior frame member and a second end received in the exterior frame member, creating a thermal barrier that prevents direct heat transfer through the metal frame while maintaining structural integrity.
2Loss of energy
If thermal separators are added to metal frames, then thermal conductivity is reduced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The thermal break is pre-assembled with tabs extending laterally from its body before insertion into the frame members. The tabs include heads and stems that are received in corresponding channels defined by the frame members, allowing the thermal break to be temporarily secured and then permanently fixed through crimping operations, simplifying the overall assembly process.
Solution Approach 2:
The tab structure of the thermal break is nested within the channel of the frame members. The channel provides a first chamber sized to receive the head and a second chamber extending from the first chamber and sized to receive the stem, creating a nested configuration that secures the thermal break firmly in place.
3Loss of energy
If thermal breaks are securely attached to frame members, then thermal performance is improved, but manufacturing precision and assembly difficulty increase
Solution Approach 1:
The thermal break is pre-assembled with tabs extending laterally from its body before insertion into the frame members. The tabs include heads and stems that are received in corresponding channels defined by the frame members, allowing the thermal break to be temporarily secured and then permanently fixed through crimping operations, simplifying the overall assembly process.
Solution Approach 2:
The crimping operation deforms the upper and lower flanges against the tab to permanently secure the thermal break to the frame members. The grooves on the tab and corresponding chambers provide self-aligning features that guide the assembly process, reducing the need for high-precision manual alignment.
4Strength
If continuous tab design with crimping is used, then mechanical interlock and structural strength are enhanced, but manufacturing complexity and production time increase
Solution Approach 1:
The thermal break is pre-assembled with tabs extending laterally from its body before insertion into the frame members. The tabs include heads and stems that are received in corresponding channels defined by the frame members, allowing the thermal break to be temporarily secured and then permanently fixed through crimping operations, simplifying the overall assembly process.
Solution Approach 2:
The crimping operation replaces traditional mechanical fastening methods with a deformation-based joining process. The upper and lower flanges are deformed against the tab to create a permanent mechanical interlock, which can be performed efficiently using automated crimping equipment to maintain high production speeds.
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 solution provides enhanced thermal performance and structural integrity by preventing thermal energy loss and maintaining component alignment during assembly, resulting in improved energy efficiency and stability of fenestration systems.
Implementation Method 1
The thermal break is made of a material having a thermal conductivity less than the thermal conductivity of the first and second members
Implementation Method 2
permanently secured to the profile by crimping the upper and lower flanges against the tab
Data Source
Figure 1
Figure 2A~2B
AI summary
A profile for a fenestration system includes first and second members, and a thermal break extending between the first and second members. The thermal break is coupled to the first member at a thermal break interconnection that includes a tab extending laterally from a body, the tab including a head extending from the body and a stem extending from the head. A channel is defined between upper and lower flanges of the first member and provides a first chamber sized to receive the head, and a second chamber extending from the first chamber and sized to receive the stem. The head is larger than the stem, and the first chamber is larger than the second chamber. The thermal break is temporarily secured to the channel by advancing the tab into the channel, and permanently secured to the channel by crimping the flanges against the tab.