Plastic Door Frame Reinforcement via Induction Heating
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Solution Overview
Problem
Current processes for manufacturing plastic door and window frames with reinforcing elements result in poor thermal insulation, energy inefficiency, high manufacturing costs, noise disturbance, and aesthetic imperfections due to drilling and screwing methods.
Innovation Solution
A process using electromagnetic induction to heat metal reinforcing elements, which then conduct heat to soften and deform the plastic frame, allowing for screwless fixation and reducing thermal conductivity, machining time, and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fixing screws are used to attach reinforcing elements to plastic profiled elements, then structural stability is improved, but thermal insulation performance deteriorates due to heat transmission through the screws
Solution Approach 1:
The invention extracts and eliminates the fixing screws from the assembly process. Instead of using screws to attach reinforcing elements to plastic profiled elements, the patent uses a compression molding process where the reinforcing elements are directly embedded into the plastic material during molding, removing the thermal bridge created by screws while maintaining structural stability
Solution Approach 2:
The invention merges the reinforcing elements and plastic profiled elements into a single integrated structure through compression molding. The reinforcing elements are embedded directly into the plastic material during the molding process, creating a unified structure that eliminates the need for separate fixing components and their associated thermal conduction paths
2Stability of the object's composition
If drilling operations are performed to insert fixing screws, then reinforcing elements can be attached, but chip formation and material waste occur
Solution Approach 1:
The invention performs the attachment action during the preliminary molding stage. The reinforcing elements are positioned and embedded into the plastic profiled elements during the compression molding process itself, before the final product is completed, eliminating the need for subsequent drilling and screw insertion operations that would generate chips and waste
3Stability of the object's composition
If drilling and screwing operations are used to fix reinforcing elements, then structural reinforcement is achieved, but processing time and manufacturing costs increase
Solution Approach 1:
The invention combines the reinforcement attachment operation with the primary molding process. By embedding reinforcing elements during compression molding, the patent eliminates separate drilling and screwing operations, significantly reducing processing time while achieving the same structural reinforcement effect
Solution Approach 2:
The invention maintains continuous useful action by performing the reinforcement attachment during the molding process itself. The compression molding operation simultaneously forms the plastic profiled element and embeds the reinforcing elements in one continuous process, eliminating idle time between molding and reinforcement attachment that would occur with sequential drilling and screwing operations
4Stability of the object's composition
If compressed air screwing systems are used to attach reinforcing elements, then fixation is achieved, but energy consumption and noise disturbance increase
Solution Approach 1:
The invention extracts and eliminates the compressed air screwing system from the process. By using compression molding to embed reinforcing elements directly into the plastic material, the patent removes the need for high-energy compressed air systems and noisy screwing operations, achieving fixation through the molding process itself
Solution Approach 2:
The invention replaces the mechanical screwing system with a thermal-mechanical molding process. Instead of using compressed air and mechanical screws to attach reinforcing elements, the patent uses heat and pressure during compression molding to embed the elements, substituting a lower-energy, quieter process for the high-energy mechanical system
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 insulation, eliminates chip formation and noise, decreases manufacturing and maintenance costs, and reduces energy consumption by eliminating drilling and improving the thermal efficiency of plastic frames.
Implementation Method 1
a heating step of a portion of the reinforcing element by means of electromagnetic induction means for obtaining a heated portion of the reinforcing element
Implementation Method 2
the heated portion of the reinforcing element is arranged in contact with a portion of the profiled element so that the heated portion of the reinforcing element conducts heat to the portion of the profiled element obtaining a softened portion of the profiled element
Data Source
Figure 1
Figure 2~4
Figure 5~7
AI summary
The process for the realization of door and window frames made of plastic material comprises: - a step of providing a profiled element (1) made of plastic material for the realization of door and window frames; - a step of providing a reinforcing element (8) made of metal material, the profiled element (1) having a containment seat (6) of the reinforcing element (8); - a step of inserting the reinforcing element (8) inside the containment seat (6); - a step of fixing the reinforcing element (8) to the profiled element (1) by means of fixing means (9) between at least a portion of the profiled element (10) and at least a portion of the reinforcing element (11); wherein the fixing step comprises a heating step of the portion of the reinforcing element (11) by means of electromagnetic induction means (12), the fixing means (9) being adapted to cooperate with at least one of the portion of the profiled element (10) and the heated portion of the reinforcing element (11) for the fixing of the portion of the reinforcing element (11) to the portion of the profiled element (10).