Flexible Connector Section for Window Frame Thermal Break
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Solution Overview
Problem
The complexity and cost of connecting structural sections in window frame assemblies using multiple connector sections, which also act as thermal breaks, make the assembly process time-consuming and expensive due to the need for high-strength, high-melting-point plastics materials.
Innovation Solution
A single elongate connector section with a flexible second leg that is more flexible in bending than the first leg, allowing for simplified assembly and consistent interengagement without additional materials, and featuring a non-slip layer for secure engagement, formed from a thermally insulative material like unplasticized polyvinyl chloride (uPVC).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple connector sections are used to connect structural sections, then thermal break function is achieved, but assembly complexity and time increase
Solution Approach 1:
The patent combines multiple connector sections into a single integrated connector that performs both connection and thermal break functions. The single connector includes a body with first and second legs that can connect to multiple structural sections while maintaining thermal insulation, thereby reducing assembly complexity while preserving the thermal break function.
Solution Approach 2:
The single connector is designed to perform multiple functions: it provides structural connection between frame sections and simultaneously acts as a thermal break. The connector's body and legs are configured to engage with multiple structural sections while the thermally insulative material maintains thermal isolation, eliminating the need for separate connection and thermal break components.
2Strength
If high-strength plastics materials are used for connector sections, then structural integrity is maintained, but material cost increases
Solution Approach 1:
The connector design applies different material properties to different parts of the structure. The first and second legs are designed with flexibility to accommodate misalignment, while the body maintains sufficient strength for structural connection. This localized differentiation allows using cost-effective thermally insulative materials without compromising overall structural integrity.
Solution Approach 2:
The patent changes the material parameter from high-strength, expensive plastics to cost-effective thermally insulative materials. The connector is designed with appropriate geometric parameters (leg flexibility, body dimensions) that compensate for the lower material strength, maintaining structural integrity while reducing material cost.
3Ease of operation
If connector sections are made flexible, then alignment tolerance is improved, but structural strength decreases
Solution Approach 1:
The connector design applies flexibility locally to the legs while maintaining sufficient strength in the body. The first and second legs are configured to be flexible in bending, allowing them to accommodate misalignment during assembly, while the body maintains the structural strength needed for connection. This localized flexibility-strength differentiation resolves the contradiction between alignment tolerance and structural strength.
4Productivity
If a single connector section is used, then assembly time is reduced, but achieving thermal break becomes more difficult
Solution Approach 1:
The single connector integrates both connection and thermal break functions into one component. The body with first and second legs provides structural connection, while the thermally insulative material throughout the connector body maintains the thermal break function. This integration achieves both rapid assembly and reliable thermal insulation in a single element.
Solution Approach 2:
The connector is designed as a multi-functional component that simultaneously performs mechanical connection and thermal insulation. The thermally insulative material is incorporated into the connector's structure, allowing it to provide both structural support and thermal break function, thereby achieving both assembly efficiency and thermal performance in a single 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
Simplifies the assembly process, reduces material costs, and ensures consistent alignment and thermal insulation by using a single connector section that is more flexible and thermally insulative, minimizing distortions and enhancing the thermal barrier properties.
Implementation Method 1
the second leg is more flexible in bending than the first leg
Implementation Method 2
the connector section is formed from a thermally insulative material like unplasticized polyvinyl chloride (uPVC)
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
An elongate connector section for connecting to a first window frame section of a window frame assembly. The connector section comprises: a body; a first leg extending away from the body transversely to a longitudinal axis of the connector section, the first leg including a first male portion for interengagement with a corresponding first female portion of the first window frame section, the first male portion including a first undercut; and a second leg extending away from the body transversely to the longitudinal axis, the second leg including a second male portion for interengagement with a corresponding second female portion of the first window frame section, the second male portion including a second undercut. The connector section is configured such that the second leg is more flexible in bending than the first leg.