Plastic Window Sash Moulding with Integrated Hinges
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Solution Overview
Problem
Traditional cast iron windows have poor insulating properties, and modern alternatives with improved insulation are costly due to complex manufacturing processes and numerous components.
Innovation Solution
A method of making windows using a plastic sash moulded with integrated functional elements, such as hinges and glazing, to avoid thermal bridges and simplify manufacturing while maintaining good insulation, and optionally embedding a metal inlay for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional cast iron windows are used, then structural strength and simplicity are achieved, but insulating properties deteriorate due to thermal bridges
Solution Approach 1:
The patent changes the material parameter from metal (cast iron) to plastic, fundamentally altering the thermal conductivity properties. This material substitution eliminates thermal bridges while maintaining structural adequacy through the plastic's inherent properties and integrated reinforcement elements.
Solution Approach 2:
The patent employs composite construction by embedding metal reinforcement elements, hinges, and glazing components directly into the plastic sash material. This creates a hybrid structure that combines the insulating properties of plastic with the strength and functionality of metal components, resolving the contradiction between insulation and structural integrity.
2Loss of energy
If modern aluminium profile windows are used, then insulating properties are improved, but manufacturing complexity and cost increase due to numerous components
Solution Approach 1:
The patent merges multiple separate components (sash, hinges, glazing, coverings, insulation) into a single integrated plastic sash unit. All functional elements are embedded directly into the molded plastic structure, eliminating the need for separate assembly steps and reducing the total number of parts, thereby simplifying manufacturing while maintaining insulation performance.
Solution Approach 2:
The plastic sash material serves multiple functions simultaneously: it provides structural support, thermal insulation, mounting surfaces for functional elements, and aesthetic finish. This multi-functionality consolidates what would traditionally require multiple separate components, reducing manufacturing complexity while preserving insulating properties.
3Reliability
If functional elements are attached separately to the sash, then attachment reliability is improved, but manufacturing complexity and number of joints increase
Solution Approach 1:
The patent incorporates functional elements such as hinges and glazing during the initial molding process of the sash. This preliminary integration ensures proper positioning and secure attachment from the outset, eliminating the need for subsequent assembly operations and reducing the number of joints while maintaining attachment reliability through the molded-in connection.
Data Source
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AI summary
The invention relates to a method for making a window, where the sash is connected to the frame by a pair of hinges, each comprising a first hinge part connected to the sash and a second hinge part connected to the frame. The sash is made from a plastic material by moulding, and that one or more functional elements are attached to the sash during the moulding thereof. The functional elements can include a stay arm having a base member, which is attached to the sash bottom member, and the first hinge parts. Also, the frame may be made by moulding.