Reinforced Window Frame Members With Shrink-Fit Thermoplastic Coating
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Solution Overview
Problem
The construction industry faces challenges with structural members that require enhanced durability and resistance to deformation, particularly in load-bearing applications, where existing materials like wood lumber lack recycling capabilities and plastic lumber may not provide sufficient structural rigidity and resistance to environmental factors.
Innovation Solution
A thermoplastic structural member is created by extruding a thermoplastic layer over a reinforcing member with a predetermined shape, utilizing a crosshead die extruder to form a unitary plastic coating that securely adheres to the reinforcing member, providing increased structural rigidity and resistance to environmental factors while allowing for easy installation and removal of inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wood lumber is used for structural members, then it provides adequate structural support, but it lacks recycling capability and is a limited resource
Solution Approach 1:
The structural member is divided into two distinct segments: a reusable thermoplastic outer layer and an internal reinforcing structure. This segmentation allows the thermoplastic portion to be removed and recycled while the reinforcing structure can be reused in another application, resolving the contradiction between structural reliability and recyclability.
Solution Approach 2:
The design enables selective discarding and recovering of materials. The thermoplastic outer layer can be discarded and recovered for recycling, while the internal reinforcing structure is preserved and reused, thereby achieving both structural support and recycling capability.
2Ease of repair
If plastic materials are used for structural members, then recycling capability is improved, but they are prone to deformation and buckling under stress
Solution Approach 1:
The structural member combines thermoplastic material with an internal reinforcing structure (such as metal or composite reinforcement) to create a composite material system. This composite construction provides both the recyclability of thermoplastic and the deformation resistance of the reinforcing structure, resolving the contradiction between recycling capability and strength.
3Strength
If a thermoplastic coating is extruded over a reinforcing member, then structural rigidity is enhanced, but the manufacturing process complexity increases
Solution Approach 1:
The manufacturing process merges the extrusion of thermoplastic coating with the formation of the internal reinforcing structure into a single integrated operation. The thermoplastic is extruded simultaneously with the placement of reinforcing elements, creating the composite structural member in one continuous process, thereby reducing manufacturing complexity while maintaining enhanced structural rigidity.
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
The solution enhances the structural integrity and durability of load-bearing members by distributing material efficiently, increasing the moment of inertia, and providing a moisture-resistant, corrosion-free structure that can withstand various loads and environmental conditions.
Implementation Method 1
extruding a thermoplastic layer over a reinforcing member with a predetermined shape to form a unitary plastic coating
Implementation Method 2
the exterior plastic layer creating an inward force on the reinforcing member as the exterior plastic layer cools and contracts to further hold the exterior plastic layer securely to the reinforcing member
Data Source
AI summary
Disclosed are frame members and mullions for a window frame that comprise a reinforcing member that is surrounded by an outer plastic layer. The outer plastic layer is held securely to the reinforcing member as a result of a waist banding effect that comprises an inward force created by the outer plastic layer as it cools and contracts around the reinforcing member. In addition, lobes are formed in the reinforcing member that assist in holding the outer plastic layer to the reinforcing member. Window inserts can be removed and replaced using adapters and removable brackets. Frame members and mullions can be built sufficiently strong to provide structural support. The frame can also be used to hold photovoltaic cells and protective coverings for photovoltaic cells. Structural members are also disclosed that have reinforcing members with apertures, debossing, scarification and/or indentations that secure the thermoplastic layer to the reinforcing member.