CA1044881A - Method of making thermal barrier lineal metal shapes - Google Patents

Method of making thermal barrier lineal metal shapes

Info

Publication number
CA1044881A
CA1044881A CA230,504A CA230504A CA1044881A CA 1044881 A CA1044881 A CA 1044881A CA 230504 A CA230504 A CA 230504A CA 1044881 A CA1044881 A CA 1044881A
Authority
CA
Canada
Prior art keywords
lineal
channels
shape
metal
insulating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA230,504A
Other languages
French (fr)
Inventor
Edward L. Chenevert
Joseph N. Laborde
Robert E. Waltman
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ethyl Corp
Original Assignee
Ethyl Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ethyl Corp filed Critical Ethyl Corp
Priority to CA230,504A priority Critical patent/CA1044881A/en
Application granted granted Critical
Publication of CA1044881A publication Critical patent/CA1044881A/en
Expired legal-status Critical Current

Links

Abstract

ABSTRACT OF THE DISCLOSURE
A method of making a thermal barrier lineal metal shape wherein metal lineal shapes are extruded or formed in such a shape as to fit the metal lineal shapes.
The insulating barrier is joined with the metal shapes by mechanical means to form a composite single-piece thermal break constructions shape. Dimensional tolerances are essential.

Description

8i METHOD OF MAKING THERMAL BARRIER LINEAL METAL SHAPES

Background of the Invention The present invention is in the field of metal construction shapes and particularly those shapes used in the construction of metal windows and doors and frames therefor.
With the advent of metal construction used in curtain wall and other metal window and door enclosures, problems of heat conduction have arisen. The use of 1~ aluminum for the metal frames caused a greater transfer of heat between wall elements than had heretofore taken place in previous types of such construction. An insula-tion problem or the necessity for a thermal break con-struction element was thus essential. Various types of thermal breaks have been constructed, some of which have been satisfactory, but have been too costly. Other types have met with varying degrees of success.
Most thermal break constructions are currently formed by pouring in place an insulating material into the metal members or by mechanically joining the metal members and insulating member by deformation of the metal members. U. S. Patents 3,204,324, 3,3g3,487, 3,624,885 and 3,634,565 are illustrative of the former type of constructions. U. S. Patents 3,093,217, 3,114,179, 3,420,026, and 3,411,995 are illustrative of the latter type of construction. U. S. Patents 3,411,254, 3,289,377, 3,o55,468 and 2,654,920 disclose additional prior art thermal break constructions.
The present invention eliminates the necessity of expensive jigs which are required with pouring operations.

- 1 - ~

In the instant invention, unit deformation force required is substantially reduced. Ileat generated by metal deformation is eliminated and metal marring and defacing is reduced.
Thermal break construction ~oints or lineal shapes of this invention have more uniform strength than prior art joints. They are simple and easy to fabricate.
The use of jig boxes and table space are minimized.
It is a primary object of the present invention to provide a thermally insulating break in metal construction shapes by a mechanical interference fit.

Summary of the Invention me present invention relates broadly to a method of forming or incorporating a thermally insulating barrier or material in metal construction shapes. Metal lineal shapes are extruded or otherwise formed in such a manner so as to accept an insulating material or barrier previously formed in such a shape as to fit or be received by the metal lineal shapes. m e insulating material is then joined with the metal shapes by mechanical means to form a composite single-piece construction material or shape. In effect, three lineal shapes, two metal and one insulating or plastic, are joined together by an inter~erence fit to form the composite building shape.
Adhesives may be applied to the metal members, plastic members or both. The insulating materials may be plastic, wood, paper, foamed plastic, nylon, PVC, urethane, styrene, polyethylene, pressed wood, "Bakelite", glass, ceramic materials and the like. Plastic is preferred and ~some reSiliency in the insulating material is also preferred.
The metal shapes are preferably aluminum and may be extruded, cQsT, wrou~ht, or othcrwlse formed. The term alumlnum includes aluminum and aluminum alloys customarlly used ln the constructlon lndustry, especially in the making of windows, doors, curtain walls and frames therefor. Aluminum extrusions are preferred.
Dimensional tolerances are essential.
This invention is defined as a method of forming a thermal barrier lineal metal construction shape comprising the steps of: aligning a pair of lineal metal shapes ad~acent each other in generally parallel spaced apart relation, each of the metal shapes having a top surface, bottom surface and vertical wall surface, and each of the metal shapes having a channel therein of a predetermined size adapted to receive a lineal insulating shape and one of the channels facing the other of the channels;
aligning ad~acent to the channels of the metal shapes and therebetween the channels, a lineal insulating shape adapted to be received by the channels, the insulating shape having a top surface, bottom surface and vertical side wall surfaces, and the insulating shape being of a predetermined size so related to the size of the channels that an interference fit is obtained when the insulating shape is inserted in the channels and, applying mechanical forces to move the channels of the metal shapes towards each other to thereby bring together the metal shapes and the insulating shape to form an interference fit between the metal shapes and the insulating shape, the interference fit occurring between the top surface and bottom surface of the lineal metal shapes and the top surface and bottom surface of the lineal insulating shape, thereby forming a unitary lineal thermal barrier construction shape.

Brief Descriptlon of the Drawings Fig. 1 is a view in cross-section illustrating the positions of one type of lineal metal shape and one type of lineal lnsulating shape ~ust prlor to belng brought together to form the unitary thermal break construction element.
A ~,f ~,, iU~
FLg. ]A Is a view simL].Ir to that o~ Fl~. 1 illustra-tin~ the unitary construction elemcnt forme~ by bringing togetllcr the lineal shapes shown in Fig. 1.
Figs. 2-5 are cross-sectlonal views illustrating alternate forms of lineal metal shapes suitable for use ln the inherent invention.
Figs. 6-10 are cross-sectional views showing alternate forms of lineal insulating members suitable for ~oining any of the various metal shapes seen in Figs. 1-5.
Fig. 11 is a top plan view illustrating one method of ~oining together the lineal metal and insulating shapes of Figs. 1-10.
Fig. 12 is also a top plan view illustrating another method of ~oining together the lineal metal and insulating shapes of Figs. 1-10.

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Description of the Preferred Embodiment Referring now to the drawings, Figs. 1J lA and
2-5 illustrate various metal shapes or receptacles which are suitable for use in the present invention. Figs. 1, lA and 6-10 illustrate various insulating member shapes or barrier concepts which may be used in the instant invention. Any of the insulating members may be Joined with any of the metal shapes and vice versa. A shape is defined as a product that is long in relation to its l~ cross~sectional dimensions and has a cross-section other than that of sheet, plate, rod, bar, tube or wire. Metal shapes may be extruded, cast, wrought or otherwise formed.
Aluminum extrusions are preferred. The insulating shape may also be extruded, cast or otherwise formed. Plastics are preferred, but all materials having thermal insulating properties are suitable.
Of the plastics, PVC (polyvinylchloride), and urethane foam are especially preferred. A cast polyurethane self-skinning foam or a free foam P~C are particularly recommended.
As can be seen in the drawings, the receptacles may be of various configurations. The opening or channel for receiving the insulating barrier is generally ~ a somewhat rectangular construction in cross-section. A
receptacle configuration such as that of Fig. 1 is preferred, wherein a plurality of teeth or small projections extend from the receptacle in the receiving area for the barrier. - -When metal shape and barrier are brought together, as seen in Fig. lA, the teeth protrude into the barrier to assist in holding it in a desired position. Suitable -adhesives may be placed in the channel of the metal shape 10~
on the barrier shape or on both such shapes so as to more firmly bond them together. With proper dimensional tolerances, gluing or adhesive joining can be eliminated entirely if desired.
A barrier or insulating member of a conflguration as seen in Fig. 7 is highly desirable as it provides a flush surface when joined with the receptacle of Figs. 1-~. me barrier of Fig. 9 is especially suitable for the receptacle of Fig. 5. The barrier of Fig. 1 is 1~) the simplest and most economical barrier shape The size and weight of the receptacles and their corresponding barrier is largely determined by strength and use specifications. In general, sizing the barrier is a function of obtaining the overall strength, i.e.
the minimum thickness required for a given application and desired interference fit within the receptacle.
For a receptacle having teeth or similar type ~ojection serrations, an interference formula of T = t + 0.3~t is desirable, when T = total barrier thickness (inches) ,~ and t = receptacle opening (inches). See Fig. l; a "T"
up to 0.270" has been tested. For a smooth receptacle, i.e. the types of Figs. 2-5, the following formula is prepared: T = t + 0.117t. Tests have been made of a "T" up to 0.160 inches.
When using aluminum, a receptacle of the type of Fig. 2 is not as desirable as the other shapes shown since aluminum has a tendency to push too far into the barrier. A hard, smooth barrier could overcome this limitation.

10~
The two lineal metal shapes and the single lineal barrier or insulating shape are joined together by an interference fit to form a composite building shape.
Predetermined designed and sized metal and barrier lineals are aligned and mechanically pushed to~;ether to form the interference fit between the barrier and the metal shapes The lineals may be aligned in a brake and then pushed together or the lineals may be moved through a series of rollers which force the ll~ shapes together as they travel past the wheels.
Adhesives may be used to supply some or all of the force required to hold the metal and barrier members together as a composite shape.
Fig. 11 illustrates one of the simplest forms of the present invention wherein lineal metal shapes 20 and 21 of the configuration of ~ig. 1 are aligned in or between brake shoes or vice faces 22 and 23 respectively, wherein the edges 24 and 25 extend into the openings or channels 26 and 27, respectively. A barrier or _3 insulating lineal shape 30 is placed between the metal shapes 20 and 21 and aligned therewith as shown in Figs. 1 and 11. When the shapes are in this aligned position, forces are simultaneously applied to the brake shoes 22 and 23 so as to move them in the directions of the arrows.
When the barrier 30 and metal shapes 20 and 21 are firmly joined together as shown in Fig. lA, the brake shoes 22 and 23 are returned to their non-compressed or open positions and the composite or unitary construction shape 35 removed from the brake.

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If desired or necessar~, a suitable adhesive may be placed on the surfaces of the receptacle openings or channels 28 and 29 or on the surfaces 32 and 33 of the member 30 which are to be placed in said openings or on all of said surfaces, In Fig, 12, which is another method of forming the interference fit, the member 20, 21 and 30 are aligned similarly as in Fig. 11 and then are moved and driven through a series of rollers 40 in the direction of the arrow 41 until the unitar~ shape or composite is formed. The rollers 40 are spaced apart at desired intervals with ever decreasing space therebetween, As the members 20 and 21 move through the rollers 40 in the direction o~ the arrow 41, the~ are moved towards the barrier 30 moving along therewith until the composite 35 is formed. The shapes 20, 21 and 30 may be fed into the roller by any suitable feed means.
Although the foregoing invention has been described in some detail by wa~ of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modi~ications may be practiced within the spirit of the invention as limited onl~ b~
the scope of the appended claims.

Claims (11)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of forming a thermal barrier lineal metal construction shape comprising the steps of:
(a) aligning a pair of lineal metal shapes adjacent each other in generally parallel spaced apart relation, each of said metal shapes having a top surface, bottom surface and vertical wall surface, and each of said metal shapes having a channel therein of a predetermined size adapted to receive a lineal insulating shape and one of said channels facing the other of said channels;
(b) aligning adjacent to said channels of said metal shapes and therebetween said channels, a lineal insulating shape adapted to be received by said channels, said insulating shape having a top surface, bottom surface and vertical side wall surfaces, and said insulating shape being of a predetermined size so related to the size of said channels that an interference fit is obtained when said insulating shape is inserted in said channels and, (c) applying mechanical forces to move said channels of said metal shapes towards each other to thereby bring together the metal shapes and the insulating shape to form an interference fit between said metal shapes and said insulating shape, said interference fit occurring between the top surface and bottom surface of said lineal metal shapes and the top surface and bottom surface of said lineal insulating shape, thereby forming a unitary lineal thermal barrier construction shape.
2. The method of Claim 1, wherein the channels for receiving the insulating shape have a plurality of projections integrally formed therein for protrusion into the insulating shape.
3. The method of Claim 2, wherein the interference fit is produced by constructing the metal and insulating shapes in accordance with the formula T = t + 0.34t, wherein T = total insulating shape thickness and t = channel opening.
4. The method of Claim 1, wherein the channels for receiving the insulating shape have substantially smooth surfaces.
5. The method of Claim 4, wherein the interference fit is produced by constructing the metal and insulating shapes in accordance with the formula T = t + 0.117t, wherein T = total insulating shape thickness and t = channel opening.
6. The method of Claim 1, wherein the channel of each lineal metal shape is formed by a pair of longitudinally extending legs joined together by a web.
7. The method of Claim 6, wherein the legs forming the channel are directed inwardly toward each other from the web joining them together.
8. The method of Claim 6, wherein the legs forming the channel are substantially parallel to each other and have an internal projection on each end thereof.
9. The method of Claim 1, wherein the lineal insulating shape has tapered and rounded edges thereon for facilitating the joining of the insulating shape with the metal shapes.
10. The method of Claim 6, wherein the legs forming the channel are substantially parallel to each other and each has an end member extending outwardly therefrom at substantially right angles or perpendicularly thereto.
11. A method of forming a thermal barrier lineal metal construction shape consisting of the steps of:
(a) aligning a pair of lineal metal shapes adjacent each other in generally parallel spaced apart relation, each of said metal shapes having a top surface, bottom surface and vertical wall surface, and each of said metal shapes having a channel therein of a predetermined size adapted to receive a lineal insulating shape, each of said channels having a plurality of projections integrally formed therein for protrusion into the insulating shape, and one of said channels facing the other of said channels;
(b) aligning adjacent to said channels of said metal shapes and therebetween said channels, a lineal insulating shape adapted to be received by said channels, said insulating shape having a top surface, bottom surface and vertical side wall surfaces, and said insulating shape being of a predetermined size so related to the size of said channels that an interference fit is obtained when said insulating shape is inserted in said channels; and (c) applying mechanical forces to move said channels of said metal shapes towards each other to thereby bring together the metal shapes and the insulating shape to form an interference fit between said metal shapes and said insulating shape, said interference fit occurring between the top surface and bottom surface of said lineal metal shapes and the top surface and bottom surface of said lineal insulating shape, thereby forming a unitary lineal thermal barrier construction shape.
CA230,504A 1975-06-30 1975-06-30 Method of making thermal barrier lineal metal shapes Expired CA1044881A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA230,504A CA1044881A (en) 1975-06-30 1975-06-30 Method of making thermal barrier lineal metal shapes

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA230,504A CA1044881A (en) 1975-06-30 1975-06-30 Method of making thermal barrier lineal metal shapes

Publications (1)

Publication Number Publication Date
CA1044881A true CA1044881A (en) 1978-12-26

Family

ID=4103486

Family Applications (1)

Application Number Title Priority Date Filing Date
CA230,504A Expired CA1044881A (en) 1975-06-30 1975-06-30 Method of making thermal barrier lineal metal shapes

Country Status (1)

Country Link
CA (1) CA1044881A (en)

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