Segmented Corner Connectors for Window Frame Stability
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Solution Overview
Problem
The existing window and door frame constructions using plastic and aluminum facings face issues with thermal expansion differences and manufacturing tolerances, leading to instability and gaps that affect the optical appearance and allow dirt penetration, especially in large lifting or sliding doors where corner connectors are not directly connected, causing deformations and uneven surfaces.
Innovation Solution
A window or door design featuring a plastic profile frame with a facing shell frame connected via first and second corner connectors, where the first connectors are larger to absorb forces and fix the glazing, and second connectors, with a smaller cross-section, compensate for deformations, ensuring a flat and stable construction by overlapping with the glazing and using recesses in the plastic frame to minimize the overall depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If corner connectors are made massive to absorb forces, then connection strength is improved, but shell depth increases and flat appearance is compromised
Solution Approach 1:
The corner connector is divided into two distinct parts: a first corner connector with large cross-section for force absorption and a second corner connector with small cross-section for positioning. This segmentation allows each part to fulfill its specific function without compromising overall design goals.
Solution Approach 2:
Different regions of the corner connector structure are assigned different properties. The first corner connector region has large cross-section for strength where forces act, while the second corner connector region has small cross-section for positioning where only minimal material is needed. This local differentiation optimizes both strength and shell depth.
2Stability of the object's composition
If aluminum facing shells are mitred and connected with corner connectors, then frame stability is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The corner connection system is segmented into two functional components with distinct roles. The first corner connector provides structural stability while the second corner connector facilitates assembly through precise positioning. This segmentation simplifies the manufacturing process by allowing each component to be optimized independently.
Solution Approach 2:
The second corner connector acts as an intermediary element that mediates between the aluminum facing shells and the first corner connector. It provides a simple positioning function that facilitates assembly while the first corner connector handles the complex force absorption, dividing the functional requirements into manageable steps.
3Reliability
If corner connectors are positioned in the glazing area to ensure stability, then fixation firmness is improved, but shell depth increases and slim design is compromised
Solution Approach 1:
The corner connector system is segmented into two parts with different functions and positions. The first corner connector is positioned in the glazing area for firm fixation, while the second corner connector is positioned in the outer area for stability. This segmentation allows the glazing area to maintain firm fixation without requiring excessive shell depth throughout the entire structure.
Solution Approach 2:
The corner connector structure implements local quality by having different cross-sections at different locations. The first corner connector has large cross-section where glazing fixation is needed, while the second corner connector has small cross-section in the outer area where only positioning is required, enabling slim shell depth in non-critical areas.
4Object-affected harmful factors
If plastic profile frame and aluminum facing shell are connected, then weather resistance is improved, but thermal expansion differences cause gaps and instability
Solution Approach 1:
The corner connector design incorporates dynamic characteristics by allowing differential movement between the plastic profile frame and aluminum facing shell. The two-stage corner connector structure with different rigidities enables the system to adapt to thermal expansion differences while maintaining overall stability and weather resistance.
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 and a homogeneous appearance while maintaining a slim shell depth, allowing for easy assembly and compensation of length changes due to temperature variations, ensuring a flush surface under all load conditions without the need for additional gluing or punctual connections.
Implementation Method 1
the first corner connectors in the facing shells preferably being arranged horizontally overlapping with the glazing at least in a partial area. Second corner connectors are arranged in the facing shells in the vertically outer area facing away from the glazing, the second corner connectors having a cross section which is significantly smaller than the cross section of the first corner connector
Implementation Method 2
due to the different thermal expansion of aluminum and plastic and unavoidable tolerances in the manufacture of the base and attachment frames
Implementation Method 3
The plastic profile frame has at least one recess on the side facing the facing shell frame in the assembled state for receiving at least one groove for receiving at least one corner connector
Data Source
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AI summary
In a window (4) or a door with a plastic profile frame (1) and a cover frame (2) connected to the plastic profile frame (1), and a glazing (4) which is positioned inside the plastic profile frame (1), wherein the cover frame (2) consists of cover panels (3) cut at a miter and connected by means of first corner connectors (6) and is arranged in the installed position to overlap horizontally with the glazing (5) at least in a partial area, wherein the first corner connectors (6) are arranged in the cover panels (3) to overlap horizontally with the glazing (5) at least in a partial area, second corner connectors (7) are arranged in the cover panels (3) in the vertically outer area, wherein the second corner connectors (7) have a cross-section which is significantly smaller than the cross-section of the first corner connectors (6).