Thermal-Break Door Frame Assembly With Integrated Anchoring Profiles
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Solution Overview
Problem
Existing door/window frame structures face challenges such as high production costs, complex manufacturing processes, limited durability, and difficulty in maintaining thermal and acoustic insulation due to non-standardized components and precise assembly requirements.
Innovation Solution
A door/window frame structure comprising a metal end element, a polymeric insulating element, and metal profiles with specific cross-sectional shapes and coupling mechanisms, allowing for easy assembly and improved thermal insulation, mechanical strength, and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating element is anchored to the frame by means of blind holes with pins or studs, then the insulating element is securely fixed to the frame, but the manufacturing process becomes complex and costly requiring high precision
Solution Approach 1:
The patent extracts the anchoring function from the insulating element itself and transfers it to the metal profile. The profile includes integrated anchoring elements (such as recesses, grooves, or protrusions) that directly engage with the insulating element, eliminating the need for blind holes and pins in the insulating element. This simplifies the insulating element manufacturing while maintaining secure anchoring.
Solution Approach 2:
The patent merges the anchoring function with the metal profile structure. The profile is designed to include both the structural function and the anchoring function in a single integrated component. The anchoring elements are formed as part of the profile manufacturing process (such as during extrusion or bending), combining multiple functions into one element and reducing overall assembly complexity.
2Reliability
If multiple specialized elements are used to make the door/window frame structure, then the structure achieves required performance, but production costs increase and standardization is reduced
Solution Approach 1:
The patent designs the metal profile to serve multiple functions simultaneously: structural support, thermal bridging control, mechanical anchoring of the insulating element, and mounting for hardware. This multi-functionality reduces the number of specialized components needed, enabling standardization and reducing production costs while maintaining structural performance.
Solution Approach 2:
The patent segments the door/window frame into modular components: a standardized metal profile, a standardized insulating element, and separate anchoring features integrated into the profile. This segmentation allows each component to be manufactured independently using standardized processes, improving production efficiency and reducing costs while maintaining overall structural integrity.
3Reliability
If the frame structure uses through holes and pins along the outline of the insulating element, then the insulating element is securely anchored, but the processing steps become delicate and require high precision
Solution Approach 1:
Instead of creating holes in the insulating element and inserting pins into it, the patent inverts the approach: the metal profile contains the anchoring features (recesses, grooves, or protrusions) that receive or engage with the insulating element. This inversion eliminates the need for precise hole alignment and pin insertion into the insulating element, reducing manufacturing precision requirements.
Solution Approach 2:
The anchoring features are pre-formed as integral parts of the metal profile during its manufacturing process (such as during extrusion or bending). This preliminary action ensures that the anchoring geometry is precisely controlled during profile manufacturing rather than during assembly, reducing the precision requirements for the final assembly step.
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 structure provides enhanced durability, thermal and acoustic insulation, simplified construction, lower production and installation costs, and versatile application, while maintaining a pleasant design.
Implementation Method 1
the insulating elements serve the function of defining a 'thermal break' between the two parts of the structure
Implementation Method 2
the metal profiles are not of the extruded type but are obtained through a bending and flanging step (carried out with bending and flanging machines), through which the profile can be given a predetermined shape and mechanical strength
Data Source
Figure 1~2
Figure 3~4d
Figure 5~6
AI summary
A door/window frame structure for making door/window casing such as doors and/or windows intended to be anchored to a supporting wall, said structure comprising at least one metal end element (2) suited to define the external surface (3) of the door/window frame and a substantially straight insulating element (4) suited to promote thermal insulation between the environments respectively located inside and outside with respect to the door/window frame structure. At least one pair of straight metal profile (13) is provided, which have a first end (16) intended to be directly coupled with the insulating element (4); at least one of the profiles of said pair has a second end (19) suited to be directly anchored to the metal end element (2).