Insulated Frame Connector Thermal Break Design
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Solution Overview
Problem
Existing insulated frame members, while providing some thermal efficiency, are not sufficient to meet the stringent requirements of modern standards such as the PassivHaus standard, particularly in reducing radiation and convection losses from glazing units to frame components.
Innovation Solution
An insulated frame member comprising inner and outer extruded metallic frame components connected by plastics connector components and filled with a foamed insulating material, where the connector components extend across the full width of the glazing unit, providing a thermal break and reducing heat conduction, and featuring a dual-walled structure for enhanced anchorage and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional connector components are used that do not extend across the full width of the glazing unit, then the device complexity is lower and ease of manufacture is better, but radiation and convection losses from the glazing unit to the frame components increase, worsening thermal efficiency
Solution Approach 1:
The connector component is divided into a dual-walled structure with an outer wall and an inner wall, creating a segmented thermal break system. This segmentation allows the connector to extend across the full width of the glazing unit while maintaining thermal efficiency by creating multiple thermal barriers rather than a single solid structure.
Solution Approach 2:
The connector component transitions from a conventional single-plane design to a three-dimensional dual-walled structure that extends across the full width of the glazing unit. This dimensional enhancement creates additional thermal break pathways and increases the thermal resistance without proportionally increasing complexity.
2Loss of energy
If connector components of greater width than the glazing unit are used, then thermal efficiency is improved by reducing radiation and convection losses, but the area of the connector component increases, potentially affecting ease of manufacture
Solution Approach 1:
The dual-walled connector structure implements local quality by creating regions of different thermal properties within the connector. The walls and the space between them provide varying levels of thermal resistance, allowing optimized heat loss reduction in critical areas while maintaining manufacturability through standardized extrusion profiles.
3Reliability
If a dual-walled connector structure extending across full width is implemented, then thermal efficiency and structural stability are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The connector component utilizes composite construction with multiple walls creating combined thermal and structural benefits. This composite structure achieves superior thermal break performance and structural stability while maintaining ease of manufacture through extrusion processes that can efficiently produce complex multi-walled profiles from single materials or material combinations.
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 significantly reduces radiation and convection losses, enhancing thermal efficiency and making the frame suitable for meeting PassivHaus standards, with potential for U values of approximately 0.8 and A energy ratings.
Implementation Method 1
a foamed insulating material, where the connector components extend across the full width of the glazing unit, providing a thermal break and reducing heat conduction
Implementation Method 2
As a result, radiation and convection losses from the glazing unit to the frame components can be reduced
Implementation Method 3
As a result, radiation and convection losses from the glazing unit to the frame components can be reduced
Data Source
Figure 1~2
AI summary
An insulated frame member comprising first and second frame components (10, 12) held in a spaced relationship by a first, glazing unit facing connector component (20) and by a second connector component (30), the first and second frame components (10, 12) together defining a void substantially filled with a foamed material (28), wherein the first connector component (20) is of width greater than or equal to the thickness of the glazing unit (18).