Roof Window Hinge Assembly and Nested Profile Design
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Solution Overview
Problem
Existing roof windows fail to maintain energy performance while replicating the appearance of traditional rooflights, particularly in conservation areas where building regulations demand specific external appearances.
Innovation Solution
The roof window design features exterior sash profile elements overlapping interior frame profile elements formed by a continuous moulding process, with a hinge assembly located within the outer circumference of the frame and sash, providing improved thermal performance and a traditional appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional cast iron roof windows are used, then the appearance resembles traditional rooflights, but the thermal efficiency is insufficient
Solution Approach 1:
The frame members are constructed as composite structures with an outer profile element providing traditional appearance and an inner profile element providing thermal insulation. This allows the roof window to simultaneously achieve the aesthetic requirements of traditional cast iron rooflights while meeting modern thermal efficiency standards through the insulating core material.
Solution Approach 2:
The frame members are formed by nesting one profile element inside another, where the outer profile element provides the traditional appearance and the inner profile element provides thermal insulation. This nested structure allows both appearance and thermal efficiency requirements to be satisfied within a single integrated component.
2Loss of energy
If insulating panes are added to meet energy performance, then thermal efficiency improves, but the appearance deviates from traditional rooflights
Solution Approach 1:
The insulating properties are concentrated in the frame members through the nested profile structure, allowing the glass panes to maintain traditional single-pane appearance while the frame provides the necessary thermal insulation. This localizes the thermal performance enhancement to the frame structure rather than requiring changes to the visible glass and glazing bar assembly.
3Reliability
If a fixed top casing is used to secure the sash, then connection reliability improves, but the traditional appearance is compromised
Solution Approach 1:
The fixed top casing that compromises appearance is removed, and the sash connection function is instead provided by the hinge assembly integrated into the frame structure. This extracts the problematic visual element while maintaining the necessary mechanical connection through an aesthetically acceptable alternative.
Solution Approach 2:
The hinge assembly serves multiple functions: it provides the rotational movement for opening the sash, maintains the connection between sash and frame, and replaces the need for a separate fixed top casing. This multi-functional approach eliminates the need for additional components that would compromise the traditional appearance.
4Ease of manufacture
If the hinge assembly is located outside the outer circumference, then installation is simpler, but thermal performance deteriorates
Solution Approach 1:
The hinge assembly is nested within the outer circumference of the frame members, positioned inside the insulating structure. This maintains the thermal envelope integrity while the hinge still provides the necessary rotational function. The nesting approach allows the hinge to be thermally isolated from the external environment.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
In the roof window (1), a hinge assembly (9) provides connection between the frame (2) and the sash (3). The hinge assembly (9) is located within an outer circumference of the frame (2) and sash (3) to provide a hinge axis at the top frame and sash members (21, 31). Each sash member (31) comprises an exterior sash profile element (31p1) and each frame member (21) comprises an interior frame profile element (21p1) formed by a continuous moulding process. The exterior sash profile element (31p1) overlaps the associated interior frame profile element (21p1) in the closed and open positions of the sash (3). The hinge assembly (9) comprises locking means (990) to prevent unintentional release of the connection between the sash (3) and the frame (2).