Composite Window Frame with Foam Thermal Break
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Solution Overview
Problem
Existing methods for modifying energy transfer through windows and doors, such as those using aluminum extrusions with thermal breaks, require complex manufacturing processes and expensive equipment, resulting in high costs and inefficiencies.
Innovation Solution
A weather barrier device featuring a glazing panel surrounded by composite support members formed from high-density foam interposed between aluminum extrusions, which simplifies the manufacturing process and enhances thermal performance by reducing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If pour-and-debridge or crimped polyamide thermal breaks are used in aluminum windows, then thermal insulation performance is improved (U factor reduced), but manufacturing complexity and equipment costs increase significantly
Solution Approach 1:
The invention extracts the thermal break function from complex multi-step processes and implements it through a simple foam insert method. The foam member is pre-formed with thermal insulation properties and inserted into a cavity in the aluminum extrusion, eliminating the need for complex pour-and-debridge or crimped polyamide processes while achieving comparable thermal performance
Solution Approach 2:
The invention creates a composite structure combining aluminum extrusion with foam insulation material. The foam member (made from materials like polyurethane or polyethylene) is inserted between aluminum extrusions to form a composite window frame that provides both structural integrity and thermal insulation, simplifying the overall manufacturing process
2Loss of energy
If pour-and-debridge or crimped polyamide thermal breaks are used, then thermal insulation is improved, but manufacturing time and production efficiency deteriorate
Solution Approach 1:
The foam member is pre-formed with the desired thermal insulation properties before insertion into the aluminum extrusion. This preliminary preparation of the insulation component allows for faster assembly compared to on-site thermal break creation methods, improving overall manufacturing efficiency
Solution Approach 2:
The invention separates the thermal insulation function into a discrete, pre-fabricated foam component that can be independently manufactured and then quickly assembled into the window frame, eliminating time-consuming on-site thermal break creation processes
3Loss of energy
If complex thermal break methods are used, then energy transfer is reduced, but manufacturing costs increase
Solution Approach 1:
The foam member is a relatively simple, inexpensive insulation component compared to complex thermal break systems. Using readily available foam materials (such as expanded polystyrene, polyurethane, or polyethylene) provides cost-effective thermal insulation without requiring expensive specialized manufacturing processes
Solution Approach 2:
The invention extracts the thermal insulation function from expensive complex processes and implements it through straightforward foam insertion into aluminum extrusions, significantly reducing manufacturing costs while maintaining effective thermal 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 solution reduces the number of manufacturing steps and costs associated with producing high-performance windows by using a composite construction with a low thermal conductivity foam core adhered to aluminum extrusions, achieving improved thermal insulation and structural integrity.
Implementation Method 1
at least one elongated structural foam member... capable of accommodating the foam member to form a composite member... reducing thermal conductivity
Implementation Method 2
The device has an adhesive applied between the foam member and the elongated rigid members
Data Source
AI summary
A composite construction for windows and doors has one or more components of the frame and/or window unit fabricated as a composite having a structural foam intermediate member onto which exterior and interior aluminum extrusions are mechanically and adhesively attached. The foam member functions as a structural bridge between the extrusions, as a thermal break and may also provide support for an internal seal to prevent air infiltration.