Monolithic Thermal Break Member for Load-Bearing Fenestration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fenestration assemblies face challenges in achieving low thermal conductivity while maintaining structural integrity and simplifying assembly, due to the high thermal conductivity of aluminum and the need for multiple parts that increase manufacturing and installation costs.
Innovation Solution
A monolithic thermal break structural member that integrates low thermal conductivity with load-bearing capabilities, serving as both a thermal break and an infill retainer, reducing the number of parts required and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the size or length of the thermal break is increased to reduce thermal conductivity, then thermal performance is improved, but structural integrity decreases because thermal breaks are not manufactured with the strength required to bear load
Solution Approach 1:
The patent combines the thermal break function and the structural support function into a single integrated member. The monolithic thermal break structural member simultaneously provides thermal insulation and bears structural loads, eliminating the need for separate thermal break inserts and structural supports. This merging resolves the contradiction by making the thermal break itself structurally competent.
Solution Approach 2:
The thermal break member is designed to perform multiple functions: it provides thermal insulation, supports structural loads, and retains infill components. This multi-functionality allows the same component to address both thermal performance and structural integrity requirements without compromise.
2Loss of energy
If multiple separate parts (pressure plates, thermal breaks, clips, gaskets) are used to achieve thermal break and secure infill, then thermal performance and structural integrity are maintained, but device complexity and assembly labor increase
Solution Approach 1:
The patent integrates multiple previously separate components (pressure plates, thermal breaks, clips, and gaskets) into a single monolithic member. This consolidation maintains the thermal and structural performance while dramatically reducing the number of parts to inventory, ship, and assemble.
Solution Approach 2:
The single monolithic member performs all the functions previously distributed across multiple components: thermal insulation, structural support, infill retention, and sealing. This universal design eliminates assembly complexity while maintaining performance.
3Reliability
If multiple separate parts are used in the fenestration assembly, then functional requirements are met, but manufacturing and installation costs increase due to more labor and higher possibility of faulty assembly
Solution Approach 1:
By combining multiple functional components into one monolithic member, the patent reduces manufacturing steps, inventory requirements, and assembly labor. The single-component design eliminates the possibility of assembly errors while maintaining all required functions.
Solution Approach 2:
The monolithic member's multi-functionality ensures that all performance requirements are met within a single component, eliminating the need for multiple specialized parts and the complex assembly process that generates labor costs and assembly errors.
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
Enhances thermal performance and structural integrity by integrating a single component that reduces heat transfer and secures glazing, while minimizing parts and assembly complexity.
Implementation Method 1
The monolithic thermal break structural member is made of a material having a low thermal conductivity... the thermal break material conductivity should not be more than 0.52 W/mK... reducing heat transfer from one side of a structure to another
Implementation Method 2
When conjoining different materials, their different thermal expansion properties will cause the conjoining elements to expand differently thus changing the strength of the connection between said conjoining elements
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided herein are thermal break structural members for use in fenestration assembly products. In some embodiments, the thermal break structural member is monolithic with an infill retainer, being designed to bear a structural load while maintaining the overall integrity and thermal performance of the conjoint fenestration unit.