News and Press: Small Upstate Manufacturer Gets Technical Boost From CUNY

Jim Devine, owner and president of Windo- Therm, a small NY manufacturing company located in Hoosick Falls near the Vermont border, knows first hand about cold weather and high heating costs. Sensing an opportunity, Devine developed the patented Windo-Therm insulation system, which he began selling to homeowners in 1998.

The sturdy Windo-Therm panel mounts on the indoor side of existing windows with weather-stripping seals to eliminate drafts and create a thermal barrier. The WindoTherm frame's two separate surfaces trap a pocket of air between them. A second air pocket is created between the Windo- Therm panel and the existing window, tripling the window's insulation value and saving as much as 55 percent on annual heating bills. "Homeowners were telling me that the product was good but I knew it could be event better", said Devine.

While Windo-Therm made old windows more energy efficient, local historic preservationists and some homeowners had an issue with the inclusion of grid work in the panels. The grids were placed to prevent extensive deflection of the aluminum frame due to thermal contraction caused by the plastic glazing materials. To satisfy customer demand and simplify the building process, the grid work in the insulating panels needed to be removed and the outer frame strengthened. "We needed a way to enhance the structural integrity of the panel, without detracting from its appearance", Explained Devine.

He then learned about the Space Alliance Technology Outreach Program (SATOP) and the free technical advice it offers from the Center for Economic Growth (CEG) in Albany, NY. Devine filled out a Request for Technical Assistance (RTA) and AJ Lucas, SATOP New York project engineer, matched the technical challenge with Ali Sadegh, a full professor at City University of New York, a SATOPAlliance Partner.

Sadegh quickly analyzed the WindoTherm frame, assessing its weaknesses and determining how to re-design the frame to minimize deflection. "Without grids, the aluminum frame could be deformed by the pulling force of the plastic glazing materials, causing air leaks. The product needed to remain air-tight for insulation purposes," said Sadegh. "I optimized the cross sectional property of the outer frame creating a new design that would minimize deflection in the acceptable range." Sadegh's suggestions resulted in a new Windo- Therm product that boasts a stronger framework and are-designed corner, both adding trength and avoiding excessive deflection. "CUNY is an invaluable Alliance Partner for SATOP," said Lucas. "Ali Sadegh is a prime example of the wealth of expertise that CUNY makes available to small business through its involvement with SATOP."

Devine couldn't be more pleased with the help he received from SATOPand CUNY. "It is really remarkable that a program like SATOP exists, offering extraordinary opportunities for people to do wonderful things," he said. "It is great that a NASA program can get this close to everyday people in small business."

Devine expects that the help he received from SATOPwill not only have a major impact on his business, but also the entire village of Hoosick Falls. "Because of the new product I have to offer, it is highly likely that I will quadruple my workforce here! While the rest of the country is losing manufacturing jobs, this SATOP program helped create work in another community," he explained.

Devine has even grander long-term plans to approach "big box" retailers with Windo- Therm and eventually branch out overseas. As long as there is cold weather and leaky windows, the sky is the limit at Windo-Therm.