T-Profile Window Frame Welding with Z-Shaped Mullion

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing T-shaped profile connections for window and door frames result in optically less advantageous V-shaped joints and difficulties in welding when frame profiles have visible surfaces at angles other than 90°, particularly in Dutch applications.

Innovation Solution

Adapting the transom profile to the contour of the frame profiles, notching the flashover chamber to match the facing surfaces, and butt-welding the profiles at right angles without introducing V-shaped notches, allowing for efficient production using contour milling, and optionally using mechanical connections or partial welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If V-shaped grooves are introduced in frame profiles for welding the fighter profile, then the fighter profile can be welded to the frame profiles, but the resulting V-shaped joints are optically less advantageous

Engineering Contradiction:

Improvewelding capabilityVSAvoidjoint appearance

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The frame profiles are pre-notched with U-shaped grooves before welding the fighter profile. This preliminary preparation creates optimal welding surfaces that eliminate the need for V-shaped grooves, achieving both good welding capability and aesthetically pleasing flush joints without visible V-shaped scars.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of creating V-shaped grooves in the frame profiles to accommodate the fighter profile, the invention inverts the approach by notching the frame profiles with U-shaped grooves that match the fighter profile's geometry. This reversal eliminates the optical disadvantage of V-shaped joints while maintaining welding feasibility.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of manufacture

If the fighter profile is cut at a V-shape taper for welding, then the fighter profile can be welded to the frame profiles, but the welding becomes difficult when frame profiles have visible surfaces at angles other than 90°

Engineering Contradiction:

Improvewelding processVSAvoidcompatibility with various angle configurations

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The fighter profile is adapted to the local contour of each frame profile through custom notching. The U-shaped grooves are specifically shaped to match the facing flashover visible surfaces of the frame profiles, allowing optimal welding contact at any angle configuration while maintaining the integrity of visible surfaces.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention changes the geometric parameters of the fighter profile's end section by notching it to match the contour of the frame profiles. This adaptation allows the fighter profile to be welded to frame profiles with various angle configurations (not just 90°), enhancing versatility while keeping the welding process straightforward.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If the visible front surface and visible rollover surface are at an angle deviating from 90°, then the design flexibility is improved, but the welding of the fighter profile becomes always difficult

Engineering Contradiction:

Improvedesign flexibilityVSAvoidwelding difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The fighter profile is pre-notched to match the contour of frame profiles with non-90° angles before welding. This preliminary adaptation creates optimal welding surfaces that accommodate various angle configurations, making the welding process straightforward despite the design flexibility of using different angles.

Inventive Principle:

Principle #10Preliminary action

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

This method produces aesthetically aligned joints suitable for various angle configurations, preventing thermal deformation and enhancing the visual appeal of the profile connections.

Implementation Method 1

a first and a second plastic frame profile are welded to one another in a straight line and a plastic fighter profile is welded at right angles thereto

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP2418347B1Method for producing a T-shaped profile connection

Publication Date: 2018.01.24 KOCHS

Figure 1a~1b
Figure 2a~2b
Figure 3a~3b

AI summary

The invention relates to a method for producing a T-shaped profile connection for a window and/or door frame, in which a first and a second plastic frame profile are welded together in a straight line, and a plastic mullion profile is attached perpendicular to this in the transition area between the first and second frame profiles, wherein the first and second frame profiles each have a front and rear visible surface, an overlap visible surface and an overlap chamber bounded by the front visible surface and the overlap visible surface, and are welded together such that the front visible surface of the second frame profile lies in a plane with the rear visible surface of the first frame profile and the mullion profile has an approximately Z-shaped cross-section with at least one central chamber and two overlap chambers.which connect to the rollover chambers of the first and second frame profiles and are each bordered by a splinter viewing surface covering the central chamber and the rollover chamber, and a rollover viewing surface.