Shape Memory Foam Connecting Web for Composite Profiles
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Solution Overview
Problem
Existing connecting webs for composite profiles, used in window, door, and facade constructions, face challenges in achieving optimal thermal insulation due to complex assembly processes and sensitivity of insulating materials, particularly polyurethane foam, which requires careful handling and increased storage and transport efforts.
Innovation Solution
A connecting web featuring a solid foam molded body made of shape memory foam that remains compressed at room temperature and expands to its original shape upon heating, allowing for easy handling and storage in a compact form, and when integrated into the composite profile, significantly enhances thermal insulation by filling cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating material is attached to connecting webs before assembly, then thermal insulation is improved, but handling and storage become more difficult due to sensitivity and space requirements
Solution Approach 1:
The insulating element is nested within a recess of the connecting web, allowing the insulation to be integrated into the structure without increasing external dimensions. This enables easy handling and storage while maintaining thermal insulation performance.
Solution Approach 2:
The insulating element is pre-mounted in a compressed state within the recess before final assembly. This preliminary positioning allows for easy storage and transport, with the insulation expanding to its full insulating capacity only when needed during assembly.
2Reliability
If insulating material is attached to connecting webs, then thermal insulation is improved, but assembly complexity increases
Solution Approach 1:
The insulating element and connecting web are merged into a single integrated component, where the insulation is permanently mounted within the recess. This eliminates the need for separate insulation installation steps, reducing assembly complexity while maintaining insulation performance.
Solution Approach 2:
The insulation is pre-mounted and secured within the recess during manufacturing, creating a pre-assembled unit. This preliminary action transfers assembly complexity from the construction phase to the manufacturing phase, simplifying on-site installation.
3Reliability
If foam insulating strip protrudes beyond plastic profile, then thermal insulation is improved, but storage and transport space requirements increase
Solution Approach 1:
The insulating element is nested within a recess of the connecting web, allowing the insulation to be contained within the overall dimensions of the connecting web. This eliminates protrusion and reduces storage and transport space requirements while maintaining insulating effectiveness.
Solution Approach 2:
Instead of extending the insulation in one dimension (protruding beyond the profile), the insulation is positioned in another dimension (within the recess depth). This dimensional repositioning maintains insulating performance while compacting the overall package for efficient storage and transport.
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 enables simplified production and handling of connecting webs while significantly improving thermal insulation properties by allowing the foam to expand and fill cavities within the composite profile upon heat treatment, providing enhanced thermal performance and stability.
Implementation Method 1
The insulating element consists of a solid foam molded body made of shape memory foam, which assumes a compressed state compared to its original shape and remains in this compressed state at room temperature and only returns to its original shape when heated above a predetermined temperature
Implementation Method 2
Only when the connecting web is attached to the outer and inner profiles and the composite profile produced in this way is subjected to a heat treatment does the foam molding expand and assume its original shape
Data Source
Figure 1~3
AI summary
The connecting web (1) has a main portion that is provided with a web-like profile portion (5) and an associated insulating element which is set in original form. A foam material shaped portion (6) made of polyurethane is compressed at room temperature in compressed state. The foam material shaped portion is returned to original shape by heating the foam material shaped portion. Independent claims are included for the following: (1) a composite structure; and (2) a method for manufacturing composite section.