Low-Profile Screen Frame Mesh Fusion Without Spline Grooves
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Solution Overview
Problem
Existing window and door screens have issues with aesthetic appearance, require exact color matching, have bulky frames, and involve labor-intensive assembly processes that include spline use and multiple manufacturing steps.
Innovation Solution
A low-profile screen frame design with a narrow profile and laser or sonic welding, adhesive bonding, and automated assembly processes, eliminating the need for splines and reducing frame dimensions, while using high-strength adhesives and unique installation hardware for centering and ease of handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional spline and groove construction is used to attach mesh to frame, then the mesh is securely held, but the frame profile becomes bulky and aesthetically unappealing
Solution Approach 1:
The invention extracts and removes the traditional groove and spline components from the frame construction. By eliminating these bulky elements, the frame achieves a sleek, low-profile appearance while the mesh is alternatively attached directly to the frame surface using adhesive, maintaining security without the visual and dimensional bulk of traditional spline systems
Solution Approach 2:
The invention replaces the mechanical spline-and-groove attachment system with a chemical adhesive bonding system. This substitution eliminates the need for grooves and splines, reducing frame profile bulk while maintaining reliable mesh attachment through the bonding action of the adhesive
2Shape
If exact color matching of screen frame to window/door frame is performed, then aesthetic appearance is improved, but inventory complexity and manufacturing cost increase
Solution Approach 1:
The invention makes the screen frame universally compatible with multiple window and door frame colors by eliminating the requirement for exact color matching. The low-profile design and alternative attachment method allow the screen to be aesthetically pleasing regardless of color coordination, enabling a single frame design to serve multiple color applications and reducing inventory complexity
3Reliability
If traditional screen frame construction with grooves is used, then mesh can be attached, but labor time and manufacturing steps increase
Solution Approach 1:
The invention extracts and eliminates the groove-cutting step from the manufacturing process. By removing the need to cut grooves into the frame, the manufacturing process is simplified and time is reduced, while the adhesive application process efficiently attaches the mesh directly to the frame surface
Solution Approach 2:
The invention replaces the mechanical groove-cutting and spline-insertion process with a simpler adhesive application process. This substitution reduces the number of manufacturing steps and assembly time while achieving reliable mesh attachment through the adhesive bonding method
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 durable, low-profile screen with reduced visibility, minimized material costs, and streamlined manufacturing, enhancing aesthetic appeal and reducing labor costs through efficient assembly and adhesive bonding.
Implementation Method 1
an adhesive is applied to a side surface of the frame, and a mesh is then applied over the adhesive
Implementation Method 2
laser or sonic welding
Implementation Method 3
laser or sonic welding
Data Source
AI summary
A screen making machine includes a table, welder assembly, and actuation assembly. The welder assembly includes: a hot air nozzle, a pump, and a roller. The actuation system moves the welder assembly along the frame. Hot air from the nozzle elevates the temperature of the mesh and adjacent frame to an elevated temperature above a melt temperature of the surfaces of the mesh and frame. The roller presses the melted mesh surface against the melted frame surface, to melt fuse them together.