Insulated Window Profile Assembly Using Elastically Clamped Flat Slats
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Solution Overview
Problem
Current methods for composing insulated window or door profiles using metal half-shells and thermally insulating profiles are limited by the need for materials with low melting temperatures, complex extrusion processes, and the inability to produce fire-resistant profiles, due to the requirement for dovetailed longitudinal edges that necessitate extrusion and complex machinery.
Innovation Solution
A method and device utilizing a flat slat-shaped insulator with a thickness greater than the groove opening, allowing for easy insertion and elastic clamping without permanent deformation, enabling the use of materials with higher melting temperatures and allowing for fire-resistant modifications, such as adding foaming and cooling strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extrusion is used to produce insulators with dovetailed longitudinal edges, then the insulators can be clamped in grooves through plastic deformation, but the choice of materials is limited to materials with low melting temperature and the production process becomes complex
Solution Approach 1:
The patent changes the geometric parameters of the insulator from a dovetailed cross-section to a substantially flat slat shape with straight longitudinal edges. This parameter change eliminates the need for extrusion processes and allows the use of materials with higher melting temperatures, including fire-resistant materials, thereby resolving the contradiction between ease of manufacture and material versatility
Solution Approach 2:
The patent extracts the requirement for dovetailed edges and extrusion processes from the insulator design. By removing this constraint, the solution allows direct cutting of flat slats from sheets and enables the use of a broader range of materials including those with high melting temperatures that were previously excluded
2Strength
If dovetailed longitudinal edges are used and clamped through plastic deformation, then the connection is strong, but the method and machine required are relatively complex
Solution Approach 1:
The patent removes the requirement for complex plastic deformation processes and specialized machines. Instead, it uses a simple elastic clamping mechanism where the insulator's straight edges are inserted into grooves with deformable lips that elastically deform during insertion and then clamp the insulator through elastic recovery, eliminating the need for complex rolling or bending machinery
Solution Approach 2:
The patent replaces the mechanical plastic deformation system (rolling, bending machines) with a simpler elastic deformation system. The deformable lips in the grooves elastically deform during insertion and then provide clamping force through elastic recovery, substituting complex mechanical processing with a simpler elastic mechanical system
3Ease of manufacture
If a flat slat-shaped insulator is used instead of extruded profiles, then production is simplified and material choices are expanded, but the insulator may require support against buckling during assembly
Solution Approach 1:
The patent applies preliminary action by providing support surfaces that prevent buckling of the slim insulator during the assembly process. The support surfaces are positioned to stabilize the insulator before the elastic clamping force is fully established, preventing buckling without requiring the insulator to have inherent high buckling resistance
Solution Approach 2:
The patent introduces support surfaces as an intermediary element between the insulator and the assembly process. These support surfaces temporarily stabilize the slim insulator during insertion and clamping, acting as a mediator that prevents buckling without becoming part of the final product structure
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 approach simplifies the production and assembly of window and door profiles, reduces material costs, and enables the creation of fire-resistant profiles without the need for extrusion, using materials with higher melting temperatures, while maintaining structural integrity.
Implementation Method 1
the deformable lip or the deformable lips of the grooves are pushed slightly apart, just enough for elastically bending the lip or the lips without permanent plastic deformation, but still sufficient to permanently develop a big elastic clamping force
Data Source
Figure 1
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Figure 5~8
AI summary
Window or door profile that is composed of two half-shells (6) in the form of profiles made from a metal such as aluminium or steel which are connected by an insulator (7) in the form of a profile made from a hard thermally insulating material, whereby the half-shells (6) are provided with an undercut groove (8) delimited by at least one deformable lip and whereby the undercut grooves (8) of the half-shells (6) are located opposite each other and with their openings facing each other, whereby the longitudinal edges (12) of the insulator (7) are only clampedly held in line with the undercut grooves (8) of the half-shells (6), characterised in that the insulator (7) substantially has the shape of a slat cut from a flat sheet, the longitudinal edges (12) of which are elastically clamped in the grooves (8) of the half-shells (6) by elastic deformation of the at least one deformable lip without plastic deformation of the material of the half-shells (6) around the grooves (8).