Thermoplastic Reinforcement for Window Profiles
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Solution Overview
Problem
Existing window profiles face challenges in achieving sufficient stability, thermal insulation, and cost-effective manufacturing, particularly due to the use of metallic reinforcements which complicate welding and require additional processing steps, and fiber-reinforced profiles exhibit poor weldability and stability.
Innovation Solution
A multi-chamber, extruded hollow profile with a thermoplastic reinforcement strip that forms a form-fit connection by profiling, eliminating the need for metallic reinforcement and complex milling processes, and utilizing thermoplastic materials with high modulus of elasticity and low moisture absorption for enhanced stability and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic reinforcement is used in the hollow profile, then the stability and strength of the profile is improved, but the thermal insulation performance deteriorates and welding complexity increases
Solution Approach 1:
The patent changes the material parameter from metallic reinforcement to thermoplastic reinforcement, fundamentally altering the thermal and mechanical properties. The thermoplastic reinforcement maintains structural stability while providing thermal insulation compatibility, eliminating the energy loss associated with metallic materials.
Solution Approach 2:
The patent uses composite construction with the thermoplastic reinforcement integrated into the hollow profile structure. The reinforcement consists of multiple layers including fabric layers and foam layers, creating a composite material system that provides both mechanical strength and thermal insulation properties simultaneously.
2Strength
If metallic reinforcement is used in the hollow profile, then the profile strength is improved, but the manufacturing complexity and production effort increase due to punching and milling requirements
Solution Approach 1:
The patent merges the reinforcement structure with the hollow profile by integrating the thermoplastic reinforcement directly into the profile during manufacturing. The form-fit connections are built into the reinforcement structure itself, eliminating the need for separate punching and milling operations that would be required for metallic reinforcements.
Solution Approach 2:
The patent changes the material parameter from metallic to thermoplastic, which fundamentally alters the manufacturing process. Thermoplastic materials can be molded and formed during extrusion, eliminating post-processing steps like punching and milling that are necessary for metallic materials.
3Ease of manufacture
If fiber-reinforced plastic profiles are used, then the manufacturing process is simplified, but the weldability and stability of the profile deteriorate
Solution Approach 1:
The patent changes the material parameter from duroplastic (fiber-reinforced plastic) to thermoplastic material. This fundamental material parameter change improves weldability because thermoplastic materials can be melted and fused during welding operations, whereas duroplastic materials cannot be remelted. The stability is maintained through the layered composite structure with fabric and foam layers.
4Device complexity
If glass fiber reinforced plastic profiles are used, then the manufacturing complexity is reduced, but the profile stability and load-bearing capacity are insufficient
Solution Approach 1:
The patent uses a multi-layer composite structure consisting of fabric layers (providing tensile strength and stability) and foam layers (providing compressive strength and insulation). This composite construction achieves superior load-bearing capacity and stability compared to simple glass fiber reinforced plastic, while maintaining manufacturing simplicity through integrated extrusion processes.
Data Source
Figure 1~2
Figure 3~5
Figure 4
AI summary
The use of a fiber-reinforced plastic material as reinforcement strips (2, 6, 7, 14, 15) of a window or door frame hollow profile (1, 10) is provided, with the fiber-reinforced plastic material having an E-module that is >8.000 N/mm2, and preferably >10.000 N/mm2, having a softening temperature of >100° C., and preferably >150° C. and an elongation coefficient of <6·10−5K−1, and preferably <5·10−5K−1 most preferably <4·10−5K−1, in particular fiber-reinforced polybutylenterephtalate, polyetylenterephtalate or a mixture thereof.