Insulated Window Frame Assembly to Prevent Delamination
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Solution Overview
Problem
Metal frame and glass pane elements with sandwich constructions suffer from delamination failures, requiring costly repairs and lengthy investigations, and there is a need for improved production methods that avoid cold-forming and extrusion processes.
Innovation Solution
A frame assembly is configured in a sandwich structural configuration with outer and inner frame assemblies joined by mounting tabs or continuous linear strips, secured with curing connection medium and mechanical fasteners, and an insulating glass unit inserted between these frames, using materials like metal and insulating body assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sandwich construction is used to insulate the frame, then thermal insulation performance is improved, but delamination failures occur reducing reliability
Solution Approach 1:
The patent applies preliminary action by pre-attaching mounting tabs to the frame members before assembly, and by designing the tab insertion features and adhesive application areas in advance. This ensures proper alignment and bonding surfaces are ready before the sandwich construction is assembled, preventing delamination by establishing strong initial bonds between layers.
Solution Approach 2:
The patent uses mounting tabs as intermediary elements between the frame members and insulating material. These tabs serve as mediators that distribute mechanical stresses and provide dedicated bonding surfaces, preventing direct contact between dissimilar materials that could cause delamination while maintaining thermal insulation performance.
2Manufacturing precision
If cold-forming and extrusion processes are used to produce frame elements, then manufacturing precision is improved, but production complexity and cost increase
Solution Approach 1:
The patent segments the frame construction into discrete components: flat frame members, separately manufactured mounting tabs, and insulating material layers. This segmentation allows each component to be manufactured using simpler, more cost-effective processes while maintaining precision through standardized connection features like tab insertion slots and pre-attached mounting elements.
Solution Approach 2:
The patent changes the manufacturing parameters from complex cold-forming and extrusion processes to simpler cutting, bending, and assembly operations. By using flat frame members cut from metal sheets and simple mounting tabs rather than complex extruded profiles, the production process complexity is reduced while maintaining sufficient manufacturing precision for the application.
Data Source
AI summary
A window element includes a frame assembly configured to support an insulating glass unit, wherein the frame assembly includes an outer frame assembly, an insulating body assembly, an inner frame assembly, stop frame assembly and divider grid. The outer frame assembly and the inner frame assembly may include a plurality of mounting tabs, or continuous linear strips aligned to be received in a corresponding slots or continuous linear grooves to form mounting tab connections with the abutting insulation body by being adhered together with curing connection medium and mechanical fasteners. An insulating glass unit is inserted and sandwiched between the inner frame assembly and the outer frame assembly within the insulated body assembly, and includes at least two glass panes that are spaced apart to provide a sealed air space therebetween to create a thermal gap.