Gas-Filled Frame Cavities for Architectural Coverings
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Solution Overview
Problem
Current insulated architectural coverings, such as garage doors and retractable storefronts, are heavy, require expensive and time-consuming assembly, and often suffer from scratches and dents during the finishing process due to post-finishing assembly of foam-insulated frames, making them difficult to automate.
Innovation Solution
A vacuum-insulated architectural covering system where panels are pivotably connected with frames having internal cavities filled with gases of lower thermal conductivity than atmospheric air, allowing for airtight interfaces and reduced material weight, enabling easier assembly and automation while preventing condensation and air leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If foam insulation is used in architectural coverings, then insulation performance is improved, but weight increases and assembly complexity increases
Solution Approach 1:
The patent extracts the insulation function from traditional foam materials and relocates it to the cavity spaces within the frame members themselves. By removing foam insulation and using the frame cavities filled with gas instead, the system eliminates the weight penalty of foam while maintaining insulation performance through the gas-filled cavities and vacuum insulation technology.
Solution Approach 2:
The patent changes the insulation mechanism from solid foam to gas-filled cavities and vacuum insulation. This parameter change involves transitioning from a solid insulation material to a gaseous or vacuum-based insulation system, which reduces weight while maintaining or improving insulation efficiency through the lower thermal conductivity of gases and vacuum.
2Ease of manufacture
If foam insulation is assembled post-finishing, then insulation can be added, but scratches and dents occur on the finishing
Solution Approach 1:
The patent applies preliminary action by integrating the insulation cavities into the frame members during the frame manufacturing process, before the finishing is applied. The cavities are formed as part of the frame structure, allowing insulation to be incorporated without subsequent assembly operations that would damage the finished surface. This eliminates the need for post-finishing assembly while maintaining surface quality.
3Ease of manufacture
If bolted frame design is used, then assembly is possible, but assembly time and cost increase
Solution Approach 1:
The patent merges the frame members into integrated assemblies where the cavities are formed as part of the frame structure itself, rather than separate bolted components. This integration eliminates the need for separate bolted assembly steps, reducing assembly time and cost while maintaining structural integrity. The frame members are designed as unified components with built-in cavity spaces.
4Loss of energy
If gas-filled cavities are used, then insulation efficiency is improved and weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent changes the approach from complex multi-component gas-filled structures to a simpler integrated frame design where cavities are formed as part of the frame members themselves. This parameter change simplifies the manufacturing process by eliminating the need for separate gas filling operations and complex sealing mechanisms, while still achieving low thermal conductivity through the cavity design.
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 system reduces material costs and weight, simplifies assembly, minimizes air leakage, and enhances insulation efficiency, leading to energy savings and improved product durability.
Implementation Method 1
Each frame member may include an internal cavity filled with a gas having a thermal conductivity less than atmospheric air
Implementation Method 2
The frame may define at least one opening within which a transparent or translucent window or other inset panel is secured... allowing for airtight interfaces
Data Source
AI summary
An apparatus for an architectural opening comprises a plurality of panels pivotably connected together. At least one of the plurality of panels comprises a frame comprising a plurality of first frame members connected to a plurality of second frame members at respective interfaces to define at least one opening. The interfaces are defined by ends of the plurality of first frame members positioned at least partially within respective apertures defined in the plurality of second frame members. Each of the first and second frame members comprise an internal cavity filled with a gas having a thermal conductivity between 2 mW/(m·K) and 25.5 mW/(m·K) at 25 degrees Celsius. The at least one of the plurality of panels also comprises an inset panel secured within the at least one opening.