What a high-end aluminum window and a plane have in common



By Bogdan Grebenyuk, Product Manager at Thermevo
on Nov 21, 2017
During the production of the aluminum window, the insulation bars of polyamide have to be accurately inserted directly into the frame profile. This requires a high-precision production process of all window components.
The world today: between climate changes and technical progress

The industrial revolution resulted in mass production of goods and general automation and this in return led to increasing of living standards of industrial nations. Unfortunately, this progress had its own downsides: due to the high level of industrialization, the atmosphere has been enriched with greenhouse gases for decades ahead. A great number of researchers and scientists are convinced that this has contributed significantly to climate shifting and the changes are still going on. The warming of the Earth's atmosphere, which is part of climate change, has brought the consequences for the entire planet. Reverting the climate change is not possible nowadays, but the damage can be mitigated to a certain degree by a significant reduction of CO2 emissions. Because of that, it is really important to increase the energy efficiency in all areas of life.

An even more precise production of technical components is necessary

Among other measures of reducing the energy consumption of buildings, the means of a higher thermal insulation level are being strongly promoted. The construction of new energy-efficient buildings, as well as the energetic enhancement of existing ones, have, however, become very complicated because of today's requirements. In order to achieve maximum energy efficiency, all components must be precisely matched - and first of all, this applies to thermal insulation of aluminum windows.

Today the production of high-end aluminum windows is comparable to the construction of airplanes. Due to the high speed and the pressure difference, the entire aircraft construction is subjected to high burdens, so every single component should be able to resist it. Safety of an aircraft construction can only be achieved by high-precision production methods.The same could be applied to the production of aluminum windows: A computer-assisted development of the insulating zones, in particular of the polyamide insulating strips, as well as a high technical precision in the production and assembly of the components, can ensure the reliability and lead to the desired energy efficiency.

In practice, the production tolerances of the components play a major role here. One example is the insertion of a middle gasket made of moss rubber into the insulation strip. Too high tolerances in the groove of the insulating profile which accommodates the central gasket lead in the worst case to the gasket being dissolved in use. But upon the other hand, if the wider gasket is installed to get more compression, it would be harder to open and close the window. And here are high-precision profiles such as a Thermevo Insulation Strip with the tolerances in the width from 0 to 0.05 mm a modern solution.

Components of a high-end aluminum window

Optics, stability, and ease of use also play an important role in aluminum windows for those who want to develop future-oriented aluminum systems, however, an effective isolation zone is absolutely vital. Insulating strips made of polyamide or the ABS insulation strips are in the center of consideration today. Their low thermal conductivity ensures efficient thermal separation of the aluminum profile parts. This can be further enhanced, for example by using polyamide insulation strips with a reduced lambda value or also by enlarging the insulating zone. A further decrease of the thermal conductivity can be achieved by using an insulating foam in the hollow chambers of the insulating profile. Due to the subsequent coating, it is important that a paintable foam is used. The thermal separation of the profiles can be further improved with reflective tape (low-E foil). This foil is applied directly to the composite strips of polyamide 6.6. Although all these measures have a relatively small influence when considered separately, altogether they have a considerable effect. And this confirms the words of the Czech writer and aphorist Pavel Kosorin:

Make not more than small steps at once, but do it every day, and you will see how great your progress is going to be.

How does the future aluminum window looks like?

A modern aluminum window consists of numerous components, that have to function as one. The trend goes towards the high-sustainability profile, able to meet the ever-increasing demands for sustainable production. This means it has to be both long-lasting and very energy-efficient. Windows, specially made just for the passive house sector today, could already become the standard in the near future. The energy efficiency and, therefore, the facade renovation of already existing buildings in order to meet modern energetic requirements will also become an issue. A second trend is the individualisation of windows for the different building project. This requires a high degree of automation in development and production, in order to offer special products at a reasonable price. It is already possible to calculate and optimize the U-values of insulating bars using software simulation.If you would like to learn more about energy efficiency and aluminum window systems, please consider subscribing to our blog.
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