Composite Window Frame Bottom Profile Drainage Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing bottom profiles of windows and doors with hollow multi-chamber profiles face challenges such as visible drainage holes on the outer wall, difficulty in accessing partitions for hole creation, and increased risk of errors and tool breakage due to the need for long tools and complex machining processes, especially with the trend towards wider profiles.
Innovation Solution
The method involves creating drainage holes in loose shells before assembly, allowing for precise placement and shorter tool usage, eliminating the need for holes in the outer wall and enabling wider profiles to be machined with standard CNC machines by machining separate shells instead of assembled profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drainage holes are made in the outer wall of the composite profile after assembly, then water drainage is achieved, but visible holes disfigure the window and door appearance
Solution Approach 1:
The drainage holes are made in the partitions before the shells are assembled and connected by insulating bars. This preliminary action allows the holes to be created when the partition is accessible, avoiding the need to punch through the finished outer wall and eliminating visible drainage holes on the exterior surface.
Solution Approach 2:
The manufacturing process is segmented into separate steps: first creating drainage holes in the partition while it's accessible, then assembling the complete composite profile. This segmentation allows the drainage function to be implemented without compromising the aesthetic appearance of the outer wall.
2Adaptability or versatility
If long tools are used to drill or mill drainage holes in partitions located at a long distance from the outside wall, then drainage holes can be created in deep composite profiles, but tool breakage risk and manufacturing errors increase
Solution Approach 1:
The drainage holes are created in the partition before the complete composite profile is assembled. At this stage, the partition is accessible and can be machined with short, stable tools, eliminating the need for long, fragile tools that would be required if holes were made after assembly in wide profiles.
Solution Approach 2:
The manufacturing process is divided so that drainage hole creation occurs as a separate preliminary step before final assembly. This allows standard CNC machines with conventional tool lengths to be used, avoiding the limitations of machine tool travel and tool stability that would constrain wider profile production.
3Shape
If covers are placed over drainage holes to hide them, then aesthetic appearance is improved, but production time increases and covers may come loose causing leaks
Solution Approach 1:
The drainage holes are created in the partition before assembly, when the partition is accessible. This eliminates the need for subsequent cover installation, as no holes are visible on the outer wall. The drainage function is achieved without compromising appearance, and without the additional time and complexity of cover installation.
Solution Approach 2:
The need for aesthetic covers is eliminated by extracting the drainage hole creation step to occur before the outer wall is finished. The drainage function is separated from the visible exterior surface, making covers unnecessary and eliminating the associated productivity losses.
4Shape
If the outer wall is recessed to hide drainage holes, then visibility is reduced, but the profile design is constrained and holes remain visible from a distance
Solution Approach 1:
The drainage holes are created in the partition before assembly, when the partition is accessible from the exterior. This eliminates the need for recessed wall designs to hide drainage holes, as the holes are not visible on the outer surface. The solution provides complete design freedom for the outer wall profile.
Solution Approach 2:
The drainage hole creation is extracted from the final assembled state and performed earlier in the process on the partition. This removes the constraint of needing recessed walls to conceal drainage holes, allowing full flexibility in outer wall design while ensuring drainage holes remain invisible from the exterior.
Data Source
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AI summary
Method to manufacture a composite bottom profile (6) of a frame (2) of a window or door (1) that is composed of hollow shells (6a, 6b, 6c) which are connected to each other by means of insulating bars (8), whereby the bottom profile (6) contains at least an outer and inner shell (6a, 6b), of which the walls facing away from each other, form an outer wall (9) and an inner wall (10) and at least one partition at a distance from these walls (9, 10) which is provided with at least one drainage hole (16), whereby the method contains the following steps: - providing at least one loose shell (6a, 6b, 6c) and/or insulating bar (8) with at. least one wall that is intended to form a partition (12) with drainage hole (16); - making one or more drainage holes (16) in this wall (12) without making a hole in the outer wall (9) or inner wall (10); - subsequently connecting the shell (6a, 6b, 6c) and/or insulating bar (8) in question with other shells by means of one or more insulating bars (8).