Window Connecting Section with Composite Profile Loop
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Solution Overview
Problem
Existing metal profiles for windows and facades face challenges in achieving a firm connection with insulating bars due to elastic springback and bending rigidity issues, limiting design options and requiring significant sheet metal thicknesses.
Innovation Solution
A composite profile design featuring a metal profile with fastening grooves formed by connected profile sections describing a profile loop, allowing for a non-positive or positive connection with insulating profiles, which enhances rigidity and reduces springback, using materials like glass fiber reinforced pultruded polyurethane for insulating profiles and sheet metal for metal profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If profile sections forming side boundaries of fastening grooves are formed jointly by a U-shaped profile section, then rigidity against bending up is improved, but design options for profile contour are restricted and sheet metal thickness must be increased
Solution Approach 1:
The profile loop is divided into separate profile sections that are connected to each other. These segmented sections can be independently formed and connected through various methods (welding, mechanical connection, adhesive bonding), enabling complex profile contours while maintaining rigidity. The segmentation allows the structure to achieve the necessary bending resistance without requiring a single thick U-shaped section, thus preserving design flexibility.
2Strength
If sheet metal thickness is increased to enable profile loops, then rigidity and resistance to springback are improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of uniformly increasing sheet metal thickness throughout the profile, the invention applies thickness increases or reinforcement only in specific critical areas where rigidity and springback resistance are most needed. The profile sections forming the fastening groove boundaries can have localized thickening or additional support structures, while other parts of the profile maintain standard thickness, optimizing both performance and manufacturability.
3Stability of the object's composition
If profile sections are connected via profile loops, then structural integrity is improved, but elastic springback of profile sections increases
Solution Approach 1:
The profile sections are pre-formed with predetermined geometries and pre-assembled into the profile loop structure before final connection. This preliminary assembly allows for pre-adjustment of fit and alignment, and the sections can be pre-stressed or pre-positioned to minimize elastic springback during subsequent connection operations. The pre-formed sections maintain their shape better during the connection process, reducing springback issues.
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 design achieves high rigidity against bending with minimal sheet thickness and reduces the tendency of springback, enabling more flexible profile contours and cost-effective production while maintaining thermal insulation and durability.
Implementation Method 1
at least one insulating profile made of a material with a low thermal conductivity compared to metal, preferably made of a plastic material
Implementation Method 2
connected to the metal profiles by pressing the fastening grooves together, e.g. by rolling, if necessary with additional embossing penetrating the insulating bar
Data Source
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AI summary
The section has a plastic insulation profile (1) whose profile contour (4) is accommodated in a fastening groove that is formed from upper and lower metal profiles (2, 3) under formation of form-fitting and/or force-fitting between the insulation profile and side limits (5) of the groove. The side limits are formed by two profile sections (6) connected with each other over a third profile section (7). A profile contour represents a profile loop in the third profile section. Fourth and fifth profile sections are adjoined to each other in an area. An independent claim is also included for a method for manufacturing a connecting section.