Mulling System Joining Plates Deflectable Seal Thermal Break
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Solution Overview
Problem
Conventional mulling systems for fenestration assemblies are inconvenient, inefficient to manufacture, and often lack sufficient thermal performance and moisture resistance.
Innovation Solution
A mulling system comprising joining plates with thermal breakers and a deflectable seal member that engages between the plates to provide a robust, moisture-resistant seal and improved thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional mulling systems are used to join fenestration units, then the assembly structure is simple, but the ease of operation deteriorates due to inconvenience and difficulty in use
Solution Approach 1:
The mulling system is divided into separate modular components: joining plates with integrated seal members, thermal breakers, and fastening elements. Each component can be independently manufactured and assembled, improving ease of operation while maintaining manageable system complexity through standardized interfaces.
Solution Approach 2:
A deflectable seal member is introduced as an intermediary element between the joining plates and fenestration units. This seal member facilitates easier assembly by providing a compliant interface that accommodates manufacturing tolerances and alignment variations, thereby improving ease of operation without significantly increasing overall system complexity.
2Manufacturing precision
If conventional mulling systems are used, then the device complexity is low, but the manufacturing precision deteriorates due to inefficiency in manufacture
Solution Approach 1:
Multiple functions are merged into integrated components: the joining plate incorporates the seal member attachment, the thermal breaker is integrated into the joining plate structure, and fastening mechanisms are built-in. This merging improves manufacturing precision by reducing assembly steps and minimizing cumulative tolerances, while the modular design keeps overall system complexity manageable.
3Temperature
If conventional mulling systems are used, then the structure is simple, but thermal performance deteriorates due to limited thermal insulation
Solution Approach 1:
A thermal breaker is introduced as an intermediary element between the joining plates that connect fenestration units. This thermal breaker, made of low thermal conductivity material, interrupts heat transfer paths through the mulling system, thereby improving thermal performance. The thermal breaker is integrated into the joining plate assembly, so the increase in system complexity is minimal while thermal performance is significantly enhanced.
4Reliability
If conventional mulling systems are used, then the device complexity is low, but reliability deteriorates due to insufficient protection against moisture intrusion
Solution Approach 1:
A deflectable seal member, essentially a flexible sealing element, is incorporated into the joining plate assembly. This flexible seal provides reliable protection against moisture intrusion by conforming to the surfaces it contacts and maintaining sealing pressure despite dimensional changes or settling. The seal member is integrated into the mulling system components, so while it increases system complexity, the improvement in moisture resistance and overall reliability is substantial.
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 mulling system enhances manufacturing efficiency, provides a robust and moisture-resistant seal, and improves thermal performance by limiting heat transfer between fenestration units.
Implementation Method 1
a deflectable seal member attached to the first joining plate and having a sealing surface that faces away from the first outer face. The sealing surface is configured to deflect and seal against the second outer face
Implementation Method 2
joining plates with thermal breakers and a deflectable seal member therebetween
Data Source
AI summary
A mulling system for a plurality of fenestration units includes a first joining plate configured to attach to a first outer edge of a first fenestration unit. The first joining plate includes a first outer face. The mulling system also includes a second joining plate configured to attach to a second outer edge of a second fenestration unit. The second joining plate includes a second outer face. The second joining plate is configured to engage the first joining plate to join together the first fenestration unit and the second fenestration unit with the first outer face facing the second outer face. The mulling system additionally includes a deflectable seal member attached to the first joining plate and having a sealing surface that faces away from the first outer face. The sealing surface is configured to deflect and seal against the second outer face of the second joining plate.