Plastic Extrusion Profile with Foam Core for Passive House Rigidity
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Solution Overview
Problem
Existing extruded profiles for door and window systems, particularly in passive houses, are complex and require multiple components to achieve both rigidity and adequate insulation, leading to increased production costs and environmental impact.
Innovation Solution
A cost-effective and energy-efficient extruded profile made of plastic, such as PVC, featuring a hollow chamber with a foam insulation core having a compressive strength of at least 0.3 N/mm², which eliminates the need for steel reinforcement and allows for simpler assembly and recycling, while maintaining high rigidity and thermal insulation properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel reinforcement profiles are used in extruded profiles, then mechanical strength and rigidity are improved, but device complexity and production costs increase
Solution Approach 1:
The patent combines the structural profile, reinforcement function, and insulation into a single integrated extruded profile made of plastic composite material. The reinforcement fibers and insulation material are embedded within the profile structure itself, eliminating the need for separate steel reinforcement profiles and reducing assembly complexity while maintaining mechanical strength.
Solution Approach 2:
The patent uses composite plastic materials containing reinforcement fibers (such as glass fibers, carbon fibers, or basalt fibers) embedded in a plastic matrix. This composite structure provides both the mechanical strength traditionally achieved with steel and the insulation properties, while being manufacturable as a single extruded component.
2Reliability
If multiple components are used to ensure rigidity and insulation, then mechanical strength and thermal insulation are improved, but manufacturing complexity and production time increase
Solution Approach 1:
The patent merges multiple functions (structural support, reinforcement, insulation) into a single extruded profile component. The profile is manufactured in one continuous extrusion process with reinforcement fibers and insulation material already integrated, eliminating the need for separate assembly steps and significantly improving productivity.
Solution Approach 2:
The reinforcement fibers and insulation material are pre-integrated into the profile structure during the extrusion process itself. This preliminary integration ensures that when the profile is installed, all structural and insulation functions are already in place, eliminating the need for subsequent assembly operations.
3Strength
If traditional extruded profiles with steel reinforcement and insulation filling are used, then mechanical strength is improved, but weight and environmental impact increase
Solution Approach 1:
The patent employs plastic composite materials with embedded reinforcement fibers that provide high strength-to-weight ratio. The plastic matrix combined with lightweight reinforcement fibers achieves the required mechanical strength while being significantly lighter than traditional steel-reinforced profiles, reducing both weight and environmental impact.
Solution Approach 2:
The patent uses recyclable plastic composite materials that can be processed and recycled more easily than steel and mixed-material assemblies. The single-material or limited-material composition facilitates recycling and reduces environmental impact compared to multi-material traditional profiles.
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 solution provides a more straightforward production process, reduced material usage, and enhanced thermal insulation, achieving high rigidity and improved U-values for passive houses without the need for additional stiffening measures, thus reducing weight and costs.
Implementation Method 1
an insulation filling made of either PS or EPS in order to achieve a good heat transfer coefficient (U-value)
Implementation Method 2
completely filled with foam so that the foam forms a firm bond with the extruded profile
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
The present invention relates to an extrusion profile, in particular made of plastic, such as PVC, for a door and/or window system, comprising at least one hollow chamber extending in the extrusion direction and bounded by profile walls, and an insulating core made of foam arranged in the at least one hollow chamber which has a compressive strength of at least 0.3 N/mm2.