Insulated Frame Member with Offset Thermal Breaks
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Solution Overview
Problem
Existing methods for producing insulated frame members with thermal breaks face challenges in achieving the required width for thermal insulation economically and designing flexible frame structures, as they often require costly and inefficient milling processes or separate screw locations.
Innovation Solution
The use of offset thermally insulating connectors between frame components, which are push-fitted and include hollow regions for enhanced thermal insulation and reduced material usage, allowing for greater design freedom and accommodating resin shrinkage without impairing the thermal break integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a wide thermal break is created by milling the extrusion, then thermal insulation is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The thermal break is segmented into multiple components: the resin material filling the channel and the separate thermally insulating connector. This segmentation eliminates the need for costly milling operations while achieving the required thermal insulation width through the combination of resin and connector materials.
Solution Approach 2:
A separate thermally insulating connector is introduced as an intermediary element between the frame components. This connector mediates the thermal break function, allowing the thermal insulation to be achieved without direct milling of the extrusion, thereby reducing manufacturing complexity and cost.
2Ease of operation
If separate screw locations are provided on frame components, then assembly is simplified, but thermal insulation is compromised
Solution Approach 1:
The screw location function is merged with the thermally insulating connector. The connector incorporates hollow regions that can receive and secure screws, combining the structural connection function with the thermal insulation function in a single element, thus maintaining thermal insulation while enabling assembly.
Solution Approach 2:
The thermally insulating connector serves multiple functions simultaneously: it provides thermal insulation, acts as a structural connector between frame components, and incorporates hollow regions for screw securing. This multi-functionality eliminates the need for separate screw locations on the frame components themselves.
3Stability of the object's composition
If connectors are rigidly fixed to frame components, then structural stability is improved, but resin shrinkage causes stress
Solution Approach 1:
The connection between the thermally insulating connector and frame components is made dynamic rather than rigidly fixed. The push-fit arrangement allows for movement and adjustment, accommodating resin shrinkage during curing while maintaining structural stability through the interlocking geometry of the connector and frame components.
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
This solution enhances thermal insulation, reduces material and manufacturing costs, and provides greater design flexibility by eliminating the need for separate screw locations and milling processes, while maintaining the integrity of the thermal break.
Implementation Method 1
first and second frame components interconnected by first and second thermally insulating connectors
Implementation Method 2
pouring a suitable resin into the channel, allowing the resin to cure
Data Source
AI summary
An insulated frame member 10 comprising first and second frame components 12, 14 interconnected by first and second thermally insulating connectors 24, 26 each connector 24, 26 defining, with the first and second frame components 12, 14 a channel 28, 30 containing a resin material 32, the connectors 24, 26 being off-set from one another.