Weld-Free Polymer Profile Connection via Internal Segmented Members
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Solution Overview
Problem
Existing polymer-based hollow chamber windows and doors require welding, which increases fabrication complexity, restricts dimension flexibility, and complicates on-site assembly, limiting their application and adjustability.
Innovation Solution
A weld-free connection construction using a connecting device that is form-fittingly arranged within the profiles, allowing for flexible adjustment and assembly without visible external components, and incorporating stiffening zones and tubular stiffening elements for enhanced strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect polymer-based hollow chamber profiles, then connection strength is improved, but fabrication complexity increases and assembly on site becomes complicated
Solution Approach 1:
The connecting device is divided into separate components: a first connecting member inserted into the first hollow chamber and a second connecting member inserted into the second hollow chamber. These segments can be independently assembled without welding, reducing fabrication complexity while maintaining connection strength through the form-fitting arrangement within the hollow chambers.
Solution Approach 2:
The connecting device acts as an intermediary element between the first and second polymer-based profiles. Instead of directly welding the profiles together, the connecting device mediates the connection by being form-fittingly arranged within the hollow chambers of both profiles, simplifying the assembly process while ensuring strong mechanical connection.
2Strength
If welding is used to connect polymer-based hollow chamber profiles, then connection strength is improved, but adaptability and flexible adjustment are reduced
Solution Approach 1:
The connecting device enables dynamic adjustment and assembly on site without requiring welding. The form-fitting arrangement within the hollow chambers allows for flexible positioning and adaptation during installation, while the mechanical interlocking provides sufficient connection strength. This dynamic assembly capability enhances adaptability for different installation scenarios.
3Strength
If welding is used to connect polymer-based hollow chamber profiles, then connection strength is improved, but profile dimension flexibility is restricted
Solution Approach 1:
The connecting device is segmented into components that can accommodate various profile dimensions. The first and second connecting members can be independently sized and configured to fit different hollow chamber dimensions, allowing the system to adapt to various profile sizes without requiring welding, thus maintaining connection strength while enhancing dimension flexibility.
4Strength
If welding is used to connect polymer-based hollow chamber profiles, then connection strength is improved, but tooling requirements and melt loss increase
Solution Approach 1:
The welding process (thermal-mechanical system) is replaced with a mechanical form-fitting connection system. The connecting device uses mechanical interlocking within the hollow chambers instead of melting and fusing the polymer profiles. This substitution eliminates melt loss entirely while maintaining connection strength through the mechanical engagement of the connecting members within the hollow chambers.
Data Source
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AI summary
The invention relates to a connection construction (1) comprising a first polymer-based profile (2) having a first end part (3) and a first hollow chamber (4) that is accessible via the first end part, a second polymer-based profile (5) having a second end part (6) and a second hollow chamber (7) that is accessible via the second end part. The first profile and the second profile are connected in a weld-free way using a connecting device (8) that comprises a first connecting member (9) that is form-fittingly arranged inside at least a part of the first hollow chamber and a second connecting member (10) that is form-fittingly arranged inside at least a part of the second hollow chamber. The connecting device is fully accommodated within said connection construction. The invention also relates to a method for fabricating a connection construction and a polymer-based hollow chamber frame (38) comprising the same.