Polyurethane Window Frame Profile with Metal Reinforcement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current window frame designs often have high carbon footprints due to complex materials and manufacturing processes, leading to increased energy consumption and complex recycling challenges, which complicates the recycling process and increases the overall carbon footprint.
Innovation Solution
A building aperture cover frame with a frame profile comprising an insulating polyurethane foam core and a polyurethane shell, where the foam core and shell are made from at least 85% and 90% polyurethane respectively, and include metal reinforcement elements between the shell and core surfaces, allowing for easier recycling and reduced carbon footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex frame designs incorporating different materials are used, then structural strength and insulation properties are improved, but recycling complexity and energy consumption increase
Solution Approach 1:
The patent merges the shell and core materials into the same polyurethane material, eliminating the need for complex separation processes during recycling. This unified material approach maintains structural strength while dramatically simplifying recycling operations, as the entire frame profile can be processed through a single recycling stream rather than requiring separation of multiple materials.
Solution Approach 2:
The patent applies homogeneity by using identical polyurethane material for both the shell and core components. This homogeneous material composition allows the frame to be recycled as a single material type, reducing recycling process complexity and energy consumption while preserving the structural integrity needed for building applications.
2Adaptability or versatility
If mixed materials are used in shell and core, then material properties can be optimized, but manufacturing complexity and carbon footprint increase
Solution Approach 1:
The patent combines the shell and core into a single polyurethane material system, which simplifies manufacturing by eliminating the need for separate material processing and assembly steps. This unified approach reduces manufacturing complexity and associated carbon footprint while still achieving the desired material properties through formulation control.
3Strength
If high-density materials are used for the shell, then structural strength is improved, but thermal insulation performance deteriorates
Solution Approach 1:
The patent applies local quality by creating a density gradient within the frame profile, where the shell has higher density for structural strength and the core has lower density for thermal insulation. This spatial variation in material density allows each region to be optimized for its specific function, with the shell providing mechanical strength and the core providing thermal resistance.
Solution Approach 2:
The patent uses composite materials with different density characteristics for the shell and core, combining high-density polyurethane in the shell for strength with low-density polyurethane foam in the core for insulation. This composite approach allows simultaneous optimization of both structural and insulating properties within a single material 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
The solution provides a frame profile with improved structural strength, thermal insulation, and reduced carbon footprint, facilitating easier recycling by using high-purity polyurethane materials and minimizing the complexity of recycling processes.
Implementation Method 1
an insulating core (6) of insulating polyurethane (PUR) foam core material... the insulating polyurethane foam core material has a thermal conductivity between 0.020 and 0.060 W/mK
Data Source
AI summary
A building aperture cover frame, such as a window frame, having at least one frame profile for framing an insulated glass unit, where the frame profile includes an insulating core of insulating polyurethane foam core material enclosed by a core surface of the insulating core, where the insulating polyurethane foam core material having at least 85% by weight polyurethane, and where the insulating polyurethane foam core material is of a material density of less than 60 kg/m3, such as less than 50 kg/m3, preferably less than 40 kg/m3, a profile shell encapsulating the insulating core and having an inner shell surface facing the core surface, where the profile shell is made of at least 90% by weight polyurethane, and where the profile shell is of a material density of at least 600 kg/m3, such as at least 750 kg/m3, preferably at least 850 kg/m3, and one or more metal reinforcement element(s) located between opposing parts of the inner shell surface and the core surface.