Polymer Security Grille Condensation Prevention

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Solution Overview

Problem

There is a need for a method to create a window with a decorative security panel that provides light transmission and security while minimizing moisture condensation, using recycled materials, and maintaining a competitive cost within the United States, with a wrought iron appearance but lighter weight to reduce transportation and retail costs.

Innovation Solution

A method involving a polymer security grille formed from high-density polyethylene, recycled graphite composite, or a mixture of urethanes and halogen-polymers, with a CNC machine cutting the design, and a seal between translucent panels to prevent fogging, which is lightweight, has a high melting point, and is environmentally friendly without VOCs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a traditional metal security grille is used, then security strength is improved, but weight increases and transportation costs rise

Engineering Contradiction:

Improvesecurity strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent changes the material parameters from traditional metal to polymer compounds (acrylic, polycarbonate, glass-filled polymer), which fundamentally alters the weight-to-strength ratio. This material substitution maintains security functionality while dramatically reducing weight, directly resolving the contradiction between security strength and weight.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material structures combining polymer matrices with reinforcing fillers or composite constructions. These composite polymer grilles achieve metal-like strength through multi-layer construction or embedded reinforcements while maintaining the inherent weight advantages of polymer materials over traditional metal alternatives.

Inventive Principle:

Principle #40Composite materials

2Strength

If a metal security grille is used, then security strength is improved, but transportation costs increase

Engineering Contradiction:

Improvesecurity strengthVSAvoidtransportation costs

Core Design Contradiction:

StrengthVSLoss of energy

Solution Approach 1:

By changing the material parameters from dense metal to lighter polymer compounds, the patent reduces the mass that must be transported. This parameter change in material density and composition directly lowers transportation energy consumption and costs while preserving the required security strength through optimized polymer formulations.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If a high-moisture security grille is used, then structural integrity is improved, but condensation occurs on translucent panels

Engineering Contradiction:

Improvestructural integrityVSAvoidcondensation

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

The patent changes the moisture content parameter of the security grille material, specifying polymer compositions with inherently low moisture absorption characteristics. This parameter modification prevents the grille from generating condensation on adjacent translucent panels while maintaining structural integrity through the selected polymer materials and their dimensional stability properties.

Inventive Principle:

Principle #35Parameter changes

4Object-generated harmful factors

If recycled materials are used, then environmental impact is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveenvironmental impactVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The patent implements material recovery processes where post-consumer or post-industrial polymer waste is collected, sorted, and reused in the manufacturing of security grilles. This recovery approach reduces environmental impact by diverting waste from landfills while the standardized recovery processes integrate smoothly into existing manufacturing workflows, managing complexity through systematic material circulation.

Inventive Principle:

Principle #34Discarding and recovering

5Shape

If complex decorative designs are cut into the grille, then aesthetic appearance is improved, but manufacturing time increases

Engineering Contradiction:

Improveaesthetic appearanceVSAvoidmanufacturing time

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical cutting methods with laser cutting technology, which uses optical energy instead of mechanical tools. This substitution enables precise, complex decorative patterns to be etched or cut through the polymer grille material much faster and with greater precision than mechanical methods, improving both aesthetic appearance and manufacturing efficiency simultaneously.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8061036B1Method for making a window with a decorative security panel

Publication Date: 2011.11.22 GLASSCRAFT DOOR

AI summary

A method for making window with a decorative polymer panel assembly. The method can include forming a polymer grille by cutting a design into a polymer with a low-moisture content. The polymer grille can have a frame portion and a design portion. A seal can be contiguously disposed about a perimeter of the frame portion. A grille assembly can be formed by disposing a translucent panel on each side of the seal, forming an air space with the polymer grille disposed within the air space. The grille assembly can be pressed, heated and cooled, forming the decorative polymer panel assembly. The decorative polymer panel assembly can be disposed within a frame which can be disposed within an opening of a structure.