Thin-Walled Insulating Web with Film Hinges for Foam-Filled Profiles
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Solution Overview
Problem
Existing methods fail to produce thin-walled insulating strips for composite profiles made of plastic with support foam in a simple, cost-effective, and reliable manner, particularly struggling with powder coating and maintaining dimensional accuracy of foam-filled hollow chamber webs, and do not allow for easy production of modular insulating bars with different functionalities.
Innovation Solution
A 4-head insulating bar design featuring thin-walled sections with film hinges and hook fasteners, allowing for the introduction of support foam into hollow chambers, which are then closed to provide structural support and facilitate powder coating, while maintaining dimensional accuracy through precise rolling mechanisms and optional relief openings for excess foam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thin-walled insulating strips are produced for composite profiles with support foam, then cost-effectiveness and ease of manufacture are improved, but dimensional accuracy and structural stability deteriorate
Solution Approach 1:
The insulating strip is divided into multiple wall sections (first, second, third, fourth wall sections) that are connected by reinforcement elements. This segmentation allows each thin-walled section to be manufactured easily while the reinforcement elements provide the necessary structural stability and dimensional accuracy when foam is introduced.
Solution Approach 2:
The insulating strip combines thin-walled plastic sections with reinforcement elements (such as metal or composite reinforcements) to create a composite structure. This composite design maintains the cost-effectiveness and ease of manufacture of thin-walled sections while the reinforcement elements provide the dimensional accuracy and structural stability needed for foam-filled applications.
2Strength
If hollow chamber webs are filled with support foam, then structural support is improved, but deformation during powder coating increases
Solution Approach 1:
Reinforcement elements are pre-installed in the insulating strip before the foam is introduced. These pre-installed reinforcements create a stable framework that prevents deformation during subsequent powder coating operations, while still allowing the foam to provide structural support.
Solution Approach 2:
Reinforcement elements are strategically positioned at specific locations within the insulating strip where deformation is most likely to occur during powder coating. This localized reinforcement provides resistance to deformation exactly where needed, while maintaining the overall lightweight and cost-effective thin-walled structure.
3Adaptability or versatility
If modular insulating bars with different functionalities are produced, then adaptability is improved, but device complexity increases
Solution Approach 1:
The insulating strip is designed as a modular structure with distinct wall sections and reinforcement elements that can be configured in different arrangements. This segmentation enables the production of various modular insulating bar designs with different functionalities by simply reconfiguring the same basic components, thereby achieving adaptability without proportionally increasing production complexity.
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
Enables the production of cost-effective, dimensionally accurate, and modular insulating bars with enhanced structural support and thermal insulation, suitable for various applications in window, door, and facade elements, with improved resistance to deformation during powder coating.
Implementation Method 1
introduction of support foam into hollow chambers
Implementation Method 2
thin-walled insulating strips for composite profiles made of plastic with a support foam
Data Source
Figure 1~2
Figure 3
Figure 4a~4b
AI summary
The invention relates to an insulating web that has two insulating web parts (23, 24) that are articulated to one another. Said insulating web can be formed with particularly thin walls, because the articulated connection enables easy filling of a hollow chamber (20h) with support foam (S).