Low-Emissivity Cavity Treatment for Enhancing Thermal Performance of Existing Window Frames

Windows contribute 40–50% of envelope heat loss despite occupying only 1/8–1/6 of the surface area. Conventional frame retrofits rely on geometry optimization or cavity insulation yet remain limited by cost and invasiveness. This study introduces electrochemical polishing to reduce cavity surface emissivity of multi-cavity broken-bridge aluminum window frames to suppress radiative heat transfer, offering a non-invasive, low-cost retrofit strategy for existing building windows. Using a typical 75-series casement window, finite element analysis (MQMC) reveals that reducing cavity surface emissivity from 0.9 to 0.05 lowers frame U-values by 12.39–30.38% and whole-window U-values by 2.72–9.69%, with full-cavity treatment outperforming insulating-cavity-only by an average of 0.29 W/(m2·K). EnergyPlus simulations across multiple climate zones show 0.74–2.26% annual heating and cooling energy savings (with max reduction of 8.99 MJ/m2·yr) in severe cold and cold regions (e.g., Harbin, Beijing), but 1.25–3.04% penalties in mild and hot-summer zones due to impeded nighttime heat rejection. At an incremental cost of 62.5 CNY/window (6.6–7.4% increase), the static payback period is 4.1 years in Harbin. The approach mitigates thermal bridging more effectively than foam-filled frames in whole-window performance. This scalable, minimal-intervention technology aligns with low-carbon retrofit imperatives for existing aging windows, particularly in heating-dominated climates.