Monolithic Window Frame via 3D Photopolymer Molding
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Solution Overview
Problem
Existing processes for manufacturing plastic window/door frameworks face challenges such as low resistance to external forces, complex and time-consuming assembly operations, increased thermal conductivity due to metal reinforcement, and difficulty in achieving a realistic aesthetic finish, leading to high production costs and inefficient output.
Innovation Solution
A process using a three-dimensional molding device that deposits and solidifies liquid photopolymer and metal-based pulverulent materials to create a monolithic perimeter frame with integrated reinforcing bars and seal elements, simplifying assembly and eliminating the need for complex extrusion processes, while also achieving a realistic wood-effect surface finish through digital mold creation and painting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal bars are inserted in containment seats to reinforce plastic profiled elements, then mechanical strength and resistance to external forces is improved, but thermal insulation performance deteriorates due to increased thermal conductivity
Solution Approach 1:
The invention uses composite profiled elements where glass fiber-reinforced plastic (GRP) bars are embedded within the plastic matrix. This composite structure provides mechanical reinforcement similar to metal bars but with significantly lower thermal conductivity, thus maintaining thermal insulation performance while improving strength and resistance to external forces.
2Reliability
If complex assembly operations are performed to seal profiled elements and fix reinforcing bars, then structural integrity is improved, but production time and device complexity increase
Solution Approach 1:
The invention integrates the reinforcing bars and seal elements directly into the profiled elements during the extrusion process. The containment seats, reinforcing bars, and seal elements form a single integrated structure, eliminating the need for separate assembly operations to fix reinforcing bars and seal elements, thus reducing device complexity and assembly time while maintaining structural integrity.
Solution Approach 2:
The reinforcing bars and seal elements are pre-positioned within the profiled elements during the extrusion process itself. This preliminary action ensures that all components are correctly positioned before final assembly, simplifying subsequent operations and ensuring structural integrity without requiring complex fixing machinery.
3Loss of energy
If traditional extrusion processes are used to create multi-chamber structures, then thermal insulation is improved, but production time and process complexity increase
Solution Approach 1:
The invention uses injection molding technology with adjustable parameters to create the multi-chamber structure directly during the molding process. By controlling injection parameters such as pressure, temperature, and injection rate, the complex multi-chamber structure with integrated reinforcing bars and seal elements can be produced in a single operation, significantly reducing production time compared to traditional multi-step extrusion processes while maintaining thermal insulation performance.
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 process reduces machinery complexity and assembly time, enhances mechanical properties, and provides a cost-effective, aesthetically appealing window/door framework with improved thermal insulation and mechanical strength, overcoming the limitations of traditional methods.
Implementation Method 1
a three-dimensional molding device (5, 6, 7, 9) which comprises at least one three-dimensional molding unit having deposition means of at least one liquid photopolymer material and solidification means of the material itself
Implementation Method 2
deposition means of at least one liquid photopolymer material and a metal-based pulverulent material and solidification means of the materials themselves, in particular a light emission unit (51) for the hardening of the liquid photopolymer material and a sintering unit (61) for the pulverulent material
Implementation Method 3
the sealing operation of the profiled elements takes place through the melting of the respective head surfaces obtained by heating the portions to be connected by means of suitable electric resistance plates
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
The process for the realization of a window/door framework (1) for walls of building comprises a molding step of a perimeter frame (2) by means of a three- dimensional molding device (5, 6, 7, 9), wherein the perimeter frame (2) comprises a plurality of perimeter sides made in a single monolithic body.