Foamed Core Window Frame with Thin Metal Layer

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Solution Overview

Problem

Traditional window and door frames, including those made from PVC and wooden cores with polyurethane shells, fail to meet stringent modern building insulation and robustness requirements, necessitating an alternative with improved thermal insulation and structural strength at a lower cost.

Innovation Solution

A frame member with a foamed core and a thin strength imparting layer, typically made of metal, providing enhanced insulation and structural strength by strategically applying the layer on selected parts of the frame member, such as the top and bottom, while using materials like thermostable expanded polystyrene and reactive hot melt adhesives for attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional wooden frames are used, then aesthetic appeal is maintained, but thermal insulation and robustness are insufficient

Engineering Contradiction:

Improvethermal insulationVSAvoidrobustness

Core Design Contradiction:

Loss of energyVSStrength

Solution Approach 1:

The frame member combines a foamed core material (providing thermal insulation with conductivity below 0.037 W/mK) and a strength-imparting layer (providing structural robustness), creating a composite structure that simultaneously achieves both thermal insulation and mechanical strength requirements

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The strength-imparting layer is applied selectively to specific regions of the frame member where structural strength is most needed, rather than uniformly across the entire frame, optimizing the balance between strength and insulation

Inventive Principle:

Principle #3Local quality

2Strength

If PVC frames are used, then robustness is improved, but thermal insulation properties are insufficient

Engineering Contradiction:

ImproverobustnessVSAvoidthermal insulation

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

The frame combines PVC or wooden core material with a foamed insulation material and strength-imparting layer, creating a multi-layer composite structure that exceeds the thermal insulation performance of traditional PVC frames while maintaining robustness

Inventive Principle:

Principle #40Composite materials

3Strength

If thicker strength imparting layers are used, then structural strength is improved, but weight increases and insulation properties deteriorate

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The invention uses a thin strength-imparting layer (typically metal foil or thin sheet) that provides sufficient structural strength while minimizing weight addition and maintaining the thermal insulation properties of the thicker foamed core material

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The composite structure allows a thin strength-imparting layer to work synergistically with the foamed core, where the thin layer provides structural integrity without significantly increasing weight or reducing insulation performance

Inventive Principle:

Principle #40Composite materials

4Strength

If complete coverage of strength imparting layer is applied, then structural strength is maximized, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The strength-imparting layer is applied selectively to specific high-stress regions of the frame member rather than providing uniform complete coverage, reducing manufacturing complexity and material usage while maintaining sufficient structural strength where needed

Inventive Principle:

Principle #3Local quality

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 achieves thermal insulation approximately 4-5 times better than wood, with improved structural strength and reduced weight, meeting stricter building regulations while maintaining aesthetic appeal and environmental sustainability.

Implementation Method 1

a core substantially made from a foamed material having a thermal conductivity below 0.037 W/m K

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3309340A1A frame member, a method for making a frame member, a frame structure and use of a frame member

Publication Date: 2018.04.18 VKR HOLDING AS

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Figure 3

AI summary

A frame member for a sash or frame structure for a window or door, said frame member comprising: a core substantially made from a foamed material having a thermal conductivity below 0.037 W/m K, wherein at least one strength imparting layer, preferably made of metal, covering at least a part of the core and the strength imparting layer has a thickness of or below 0.1 mm, preferably below 0.06 mm.