EP0110340B1 - Production method for insulated composite sections for window frames or the like, metal section for using the method on and splitting tool for applying the method - Google Patents

Abstract

1. Method for the production of thermally-insulated composite sections for window frames or the like, which have at least two metal section parts (1, 2), which are connected with each other through at least one intermediate piece (15) of thermally insulating material, in which the two metal section parts are firstly integrally connected with each other by at least one connecting cross-piece (3) of the same material, and at least one channel (11), preferably open to the exterior, being formed and being filled with the thermally insulating material forming the intermediate piece, and in which, after hardening of the insulating material, the connecting cross-piece is separated at predetermined, weakened separation points (20) and removed, characterised in that the connecting cross-piece is continuously subjected to a tensile load, acting in the plane of the connecting cross-piece and transversely to its longitudinal extent, in the transition zone (20) between the connecting cross-piece and the metal section parts connected therewith in the longitudinal direction, and is thereby continuously separated from the metal section parts.

Description

The invention relates to a method for producing thermally insulated composite profiles for window frames or the like, which have at least two metal profile parts which are connected to one another via at least one intermediate piece made of heat-insulating insulating compound, the two metal profile parts being first connected to one another in one piece by at least one connecting web made of the same material and as a result, at least one groove, which is preferably open to the outside, is formed, which is poured out with the heat-insulating insulating compound forming the intermediate piece and, after the insulating compound has hardened, the connecting web is cut off and removed at predetermined, weakened separation points.

The method of the type described at the outset is known in principle from DE-B-1245567. However, the removal of the connecting web is problematic if the composite profile is designed as a hollow profile, two opposite sides of the cavity being formed by the metal profile parts and the two other, opposite sides of the cavity being formed by two intermediate pieces made of heat-insulating insulating compound. In such an arrangement, as shown for example in DE-A 29 39 898, the connecting webs forming the channel bottom lie on the inside of the profile cavity and are therefore no longer freely accessible. From DE-A 29 39 898 it is now known to separate the two opposite connecting webs from the metal profile parts either by machining with the aid of a broach or with the aid of a drawing mandrel which has cutting edges extending transversely to the longitudinal center plane. In addition, a separation method is known from the aforementioned prior publication, in which the ends of the connecting webs to be separated, which are bent into the cavity, are gripped by a pair of pliers and then sheared off along a molded-in point in the manufacture of the initial profile when pulled through the hollow profile. The methods mentioned have considerable disadvantages. As far as the tools are provided with cutting edges, there is a considerable effort in maintaining the tools, since it must be ensured that the cutting edges are always sufficiently sharpened. In the last-described method, in which the connecting webs are torn off essentially under shear stress, there is a risk that the adjacent metal profile parts are at least partially bent by the separating process and the positive connection between the metal profile part and the heat-insulating intermediate piece is at least partially loosened, since the entire arrangement is subjected to a combined bending-shear stress in the separation area by the separation process, so that stresses of the profile arrangement which cannot be precisely defined occur here.

From DE-A 31 17 817 a method is also known in which the connecting webs forming the channel bottom are connected to the metal profile in such a way that a gap extending in the longitudinal direction remains between the connecting web and the metal profile, in which to separate the connecting web a wedge-shaped cutting tool can be inserted. The transition zone between the metal profile and the connecting web in the region of the gap is also designed as a predetermined breaking point. The separation process in this known profile, however, takes place in such a way that the connecting web is torn off the metal profile perpendicular to its plane, the wedge-shaped cutting tool being supported in the gap area both on the edge of the connecting web and on the metal profile. As a result, part of the separating force acts directly on the webs delimiting the chamber filled with insulating compound. As a result, there is a risk that these webs will be deformed and the bonded zone in this area will be stressed by stresses from the metal profile. This can have a negative effect on the positive or positive connection between the insulating material filling and the associated metal profiles and ultimately lead to the entire plastic composite and the two shells of the metal profile shifting against one another during the cutting process, since the metal profiles also require the tools required for guiding the cutting tool Have to absorb forces.

The invention has for its object to provide a method of the type mentioned, by means of which the process of removing the connecting web is improved.

The object is achieved according to the invention in that the connecting web in the transition region between the connecting web and the metal profile parts connected to it continuously in the longitudinal direction one acting in the plane of the connecting web and transversely to its longitudinal extent. Subject to tensile stress and is continuously separated from the metal profile parts. This procedure results in a definable stress on the overall profile, so that here the connecting web is properly separated without the metal profile parts being adversely deformed by the cutting process. It is expedient if the tensile load is applied simultaneously and symmetrically, so that the connecting web is separated from the metal profile parts on both sides in one operation.

In a preferred embodiment of the invention it is provided that the tensile load is limited by deformation of the connecting web and ver with the metal profile parts bound bending profile parts is generated. Such a deformation of parts of the remaining metal profile parts, which can be precisely defined via the shape of the bending profile parts, results in a clear tensile stress in the region of the separation point, so that unintentional deformations which impair the use of the composite profile produced are avoided.

In a preferred embodiment of the method it is further provided that a transverse force for detaching the connecting web from the intermediate piece of insulating compound is applied to the connecting web at a distance behind the separation point and continuously in accordance with the progress of the separation. This action on the part of the connecting web which has already been cut off results in a perfect detachment from the insulating compound even if these parts are not or only insufficiently provided with a separating agent when the channel-shaped parts are poured out with insulating compound.

The invention further relates to a metal profile for the production of thermally insulated composite profiles for window frames or the like, for carrying out the method, which has at least two metal profile parts which are integrally connected to one another via at least one connecting web made of the same material and form an open channel for receiving a heat-insulating insulating compound.

Such a metal profile as a starting profile for the production of thermally insulated composite profiles is known for example from DE-A 29 39 898.

The metal profile according to the invention is characterized in that the metal profile parts at the transition point to the connecting web are each provided with a bending flange projecting beyond the rear web surface and that the wall thickness of the transition point to the connecting web and bending flange is thinner than that of the connecting web on the one hand and that of the bending flanges in the area of the Transition point on the other hand. A metal profile designed in this way makes it possible to optimally design the two profile parts in relation to the requirements of the composite profile without having to take the separation process into account in the wall thickness in individual areas. This is done by designing the bending flange, which is dimensioned in such a way that it transmits the forces required for removing the connecting web from the tool to the transition point forming the dividing line. At the same time, the shape of the bending flange can ensure that the forces acting on it during the cutting process do not have a deforming effect on the other areas of the metal profile parts. Another advantage is that after the separation between the bending flange and the connecting web there is a slightly larger space due to the deformation of the bending flange, so that the connecting web can be removed from the composite profile without any problems. By appropriate shaping the transition point between the connecting web and the bending flanges delimiting it is shaped in cross section so that the transition point forms a predetermined breaking point and thus defines a defined separation area.

In a preferred embodiment of the invention it is provided that the bending flanges each have a V-shaped cross section, one leg of which ends at the respective metal profile part and the other leg of which is connected to the connecting web in the region between the apex and the free end, part of the length of the free leg protrudes beyond the back surface of the connecting web. With such a shape of the bending flange, with appropriate assignment of the transition point to the connecting web, precise lever ratios can be defined, so that effects on the metal profile parts are clearly avoided.This is particularly possible if the wall thickness of the leg of the bending flange connected to the connecting web is in the area of the apex is lower than in the other areas. Another advantage of the approximately V-shaped cross section of the bending flange is that it can simultaneously be used for anchoring the intermediate web formed from insulating compound and is thus an integral and load-bearing component of the composite profile.

In a preferred embodiment of the invention, guide means extending in the longitudinal direction of the profile are also provided for the tool for deforming the bending flanges. These can either consist of an inserted guide rail for the tool or, according to a preferred embodiment of the invention, can already be arranged on the back surface of the connecting web. The guide means can consist of a web-shaped guide extension that extends in the longitudinal direction of the profile. A guide projection with a T-shaped cross section is also expedient, which at the same time offers the possibility of detaching the part of the connecting web which has already been separated from the metal profile parts from the intermediate piece made of insulating compound.

The invention further relates to a cutting tool for performing the method with a tension element on which a tool head is arranged. The separating tool is designed according to the invention in such a way that the tool head, based on the direction of passage, has a front guide part for support on the undivided profile and a deforming part widening in a wedge shape against the rear tool end and engaging the bending flanges. This tool has the advantage that the reaction forces to the deformation forces acting on the bending flanges are absorbed by the tool from the still unseparated areas of the profile, so that the intermediate pieces made of insulating compound are not stressed by the separating process.

In a preferred embodiment, a longitudinal groove is provided on the surface of the tool head facing the connecting web to be removed, for receiving a guide projection on the connecting web or an inserted guide rail. As a result, the absorption of the reaction forces to the deformation forces acting on the bending flanges is further improved, since the two metal profile parts are not loaded with a tool designed in this way and with a corresponding profile.

• Figur. 1 ein Ausgangsprofil,
• Figuren 2 bis 6 die einzelnen Schritte der Herstellung eines Verbundprofils aus dem Vorprofil gemäß Fig. 1,
• Figur 7 eine Darstellung des Arbeitsschrittes entsprechend Fig. 5 (Trennen des Verbindungssteges) bei einem Profil mit größerem Querschnitt,
• Figuren 8, 9 + 10 ein Verbundprofil entsprechend Fig. 6 mit verschiedenen Anordnungen wärmedämmender Zwischenlagen,
• Figur 11 eine andere Ausführungsform für ein Vorprofil,
• Figur 12 eine Aufsicht auf ein Trennwerkzeug zur Herstellung des Verbundprofils gemäß Fig. 6,
• Figur 13 eine Stirnansicht des Werkzeuges gemäß Fig. 12,
• Figur 14 eine Seitenansicht des Trennwerkzeuges gemäß Fig. 12.

The invention is explained in more detail with reference to schematic drawings of exemplary embodiments. Show it :

• Figure. 1 an initial profile,
• FIGS. 2 to 6 show the individual steps for producing a composite profile from the preliminary profile according to FIG. 1,
• FIG. 7 shows the work step corresponding to FIG. 5 (separating the connecting web) in the case of a profile with a larger cross section,
• FIGS. 8, 9 and 10 a composite profile corresponding to FIG. 6 with different arrangements of heat-insulating intermediate layers,
• FIG. 11 another embodiment for a preliminary profile,
• FIG. 12 shows a plan view of a separating tool for producing the composite profile according to FIG. 6,
• FIG. 13 shows an end view of the tool according to FIG. 12,
• FIG. 14 shows a side view of the cutting tool according to FIG. 12.

The metal profile shown in a section in FIG. 1 for producing a thermally insulated composite profile essentially consists of two metal profile parts 1 and 2, which are purpose-formed in accordance with the specified use. Since only the bonded area with the connecting pieces made of heat-insulating insulating material, which will be described in more detail below, is of interest here, the shape for the required use is not shown here.

In the exemplary embodiment shown, the two metal profile parts 1 are shaped symmetrically and are firmly connected via two connecting webs 3, which run parallel to one another and are made of the same material. The two metal profile parts 1 and 2 are also provided on their sides facing the connecting webs 3 with retaining webs 4, to which the bending flanges 5 are formed with an approximately V-shaped cross section. One leg 6 of the V-shaped cross section is connected to the holding web 4, while the other leg 7 is connected to the connecting web 3. The connection point between the leg 7 and the connecting web 3 is in the region between the apex and the free end, so that the free end of the leg 7 projects beyond the back surface 8 of the connecting web. The other, the metal profile part 1 or 2 facing the end of the leg 7, here in the region of the apex 9 when using a V-shaped cross section for the bending flange, is dimensioned smaller in wall thickness than in the other areas, so that for the following deformation process described in more detail results in a clear bending line.

A profile is formed from the two metal profiles 1 and 2 and the connecting webs 3 connecting them, which has two channels 11 open to the outside. With respect to the grooves 11, the metal profiles 1 and 2 are each provided with fianches 12 which protrude beyond the groove opening, so that in cooperation with the profile of the bending flanges 5 there is a hook-shaped cross-sectional shape in this area.

The metal profile shown in FIG. 1 shows the initial shape produced, for example, by extrusion.

2 shows the next manufacturing step for producing a composite profile. In this case, from the free edge of the flanges 12 of the metal profile parts 1, 2 covering the channel opening, a multiplicity of claw-like projections 14 are produced in the longitudinal direction of the profile in the manner of claws. Then, as shown in FIGS. 3 and 4, the channels 11 are successively filled with an insulating compound, for example by casting, which each form the insulating intermediate piece 15 on the finished composite profile.

As can be seen from FIGS. 3 and 4, the transition area facing the intermediate piece 15 between the connecting web 3 and the leg 7 of the bending flange 5 is shaped in such a way that an approximately V-shaped contour results and thus the connection between the leg 7 and the connecting web 3 is the thinnest Has wall thickness. The connecting web 3 also has on its side facing away from the channel a continuous, web-shaped guide projection 16, the meaning of which will be explained in connection with the separation process described in more detail below. Furthermore, the connecting web 3 can be provided on its side forming the channel bottom with a further web-shaped extension 17, which offers additional design options for the finished composite profile, which will be described in more detail below. As can also be seen from FIG. 3, a positive connection between the two metal profile parts 1 results both from the shape of the bending flanges 5 and from the claw-like bent lugs 14 which are embedded in the insulating compound forming the intermediate piece 15 after the channel has been poured out , 2 and the intermediate pieces 15.

In order to create a thermally insulated composite profile, the connecting webs 3 have to be separated out, so that only the intermediate pieces 15 remain as the only connection between the metal profile parts 1 and 2. This process is explained in more detail with reference to FIG. 5. After the insulating compound has hardened and thus solid intermediate pieces 15 have been formed from insulating compound, the profile in 4, a separating tool is inserted into the cavity 17, which usually consists of a tensile element extending over the entire profile length, to which a tool head is attached. In the present case, as will be explained in more detail with reference to FIG. 12, the tool head essentially consists of a wedge-shaped deformation part 18, which is shown in FIG. 5 in its largest cross-sectional area. If such a tool head is pulled through the cavity 17, the free ends of the legs 7 of the bending flanges 5 are continuously bent against the metal profile parts 1, 2 by the wedge-shaped side lugs 19. Here, the connection point 20 between the leg 7 and the connecting web 3 (FIG. 3) is subjected to a defined tensile stress and the connecting web is simultaneously separated from the two bending flanges 5. This deformation process simultaneously creates a small space 21 in this area, so that the connecting web 3, which has now been separated, is exposed and can be pulled out after the tool head has been completely pulled through.

Since the connecting webs 3 have a web-shaped guide projection 16 which points into the cavity 17 and to which a corresponding slot 22 in the tool head is assigned, the reaction forces which occur when the bending flanges 5 are deformed are transmitted via the guide projection 16 to the connecting web 3. If one now provides the tool head, as will be described in more detail with reference to FIG. 12, with a leading guide part, the reaction forces are fully absorbed by the as yet unseparated profile via the guide lugs 16, so that the only connection between them is then by the separating process the metal profile parts 1 and 2 representing intermediate pieces 15 made of insulating material are not claimed. Experiments have confirmed that when the intermediate webs 3 are removed from an initial profile according to FIG. 1, that is to say without the stabilization by the intermediate pieces 15, no reaction forces are transmitted to the metal profile parts 1, 2 behind the separation point. 1, there was no change in the distance between the two metal profile parts 1, 2 from one another after the separation.

The finished composite profile is shown in cross section in FIG. 6.

Fig. 7 shows a composite profile with a larger cross-section, i. H. with a greater distance between the intermediate pieces 15. The arrangement of the connecting webs 3 and the bending flanges 5 corresponds to the embodiment described with reference to FIGS. 1 to 6. The only difference is that the metal profile parts 1 ', 2' in the region of the cavity 17 have additional guide lugs 23 on which the cutting tool rests, so that smaller tool heads can be used. Again, the reaction forces are absorbed via a guide shoulder 16 on the connecting web 3 and a corresponding longitudinal slot 22 on the tool head.

8, 9 and 10 show advantageous design options for a composite profile according to FIG. 6. As can be seen from FIG. 8, heat-insulating, strip-shaped intermediate layers 24 can be inserted on one or on both sides into the remaining free space of the bending flange 5, so that heat transfer by radiation through the cavity 17 from one metal profile part to another is also prevented.

As can be seen from FIG. 9, such an intermediate wall can also be drawn in in the central region if a corresponding groove-shaped recess is formed in the intermediate pieces 15 with the aid of a corresponding extension on the connecting web 3 (FIG. 3).

Fig. 10 shows an arrangement in which three partitions 24 are retracted.

FIG. 11 shows a cross-sectional profile corresponding to FIG. 1, which has only been changed so that the guide projection 16 'has a T-shaped profile cross-section. Otherwise, the profile corresponds to the embodiment according to FIG. 1. The tool head for removing the connecting web 3 in this profile must be provided with a hammer head groove corresponding to the cross-sectional shape of the guide projection 16 ', so that the tool head for absorbing the reaction forces on the guide projection is also here 16 'can support. With a guide projection 16 'shaped in this way, however, the hammer head groove is guided in the tool head in such a way that the distance of the part of the groove forming the hammer head part from the surface of the tool head facing the connecting web is greater by a distance behind the region of the deformation part 18, based on the direction of passage , so that when pulling the tool head over the T-shaped projection 16 'on the two connecting webs 3 forces are exerted in the direction of the arrows 25 which, after the connecting webs 3 have been separated from the bending flanges 5, lift them off from the intermediate pieces 15.

FIG. 12 shows a top view of a tool head 26 for machining a cross-sectional profile corresponding to FIG. 1. The tool head 26 is pulled in the direction of arrow 27 (direction of passage) through the cavity 17 through the composite profile in the form according to FIG. 4. For this purpose, the tool head is connected to a tension element, not shown. The tool head is provided on the top and bottom with a longitudinal groove 22 for receiving the guide projection 16 on the connecting web 3. The tool head 26 is in a front guide part 28 and an adjoining, wedge-shaped against the rear tool end deforming part 29 un divided. The cross-sectional area shown in FIG. 5 corresponds to the section line VV in FIG. 12.

FIG. 13 shows a view in the direction of arrow 13, FIG. 14 shows a side view.

Claims (22)

1. Method for the production of thermally-insulated composite sections for window frames or the like, which have at least two metal section parts (1, 2), which are connected with each other through at least one intermediate piece (15) of thermally insulating material, in which the two metal section parts are firstly integrally connected with each other by at least one connecting cross-piece (3) of the same material, and at least one channel (11), preferably open to the exterior, being formed and being filled with the thermally insulating material forming the intermediate piece, and in which, after hardening of the insulating material, the connecting cross-piece is separated at predetermined, weakened separation points (20) and removed, characterised in that the connecting cross-piece is continuously subjected to a tensile load, acting in the plane of the connecting cross-piece and transversely to its longitudinal extent, in the transition zone (20) between the connecting cross-piece and the metal section parts connected therewith in the longitudinal direction, and is thereby continuously separated from the metal section parts.

2. Method according to Claim 1, characterised in that the tensile load is applied simultaneously and symmetrically, so that the connecting cross-piece is separated in one process step on both sides from the metal section parts.

3. Method according to Claim 1 or 2, characterised in that the sensile load is produced by deformation of bending section parts (5) which delimit the connecting cross-piece and are connected with the metal section parts.

4. Method according to one of Claims 1 to 3, characterised in that a transverse force is applied onto the connecting cross-piece at a distance behind the separation point and continuously corresponding to the progress of separation, to detach the connecting cross-piece from the insulating material.

5. Metal section for the production of thermally insulated composite sections for window frames or the like, by the method according to Claims 1 to 4, having at least two metal section parts, which are integrally connected with each other through at least one connecting cross-piece of the same material and form an open channel to receive a thermally insulating material, characterised in that the metal section parts (1, 2) are provided in each case with a bending flange (5) jutting out over the rearward cross-piece surface (8) at the transition point (20) to the connecting cross-piece (3), and that the wall thickness of the transition point (20) between the connecting cross-piece (3) and the bending flange (5) is thinner than that of the connecting cross-piece (3) on the one hand, and that of the bending flange (5) in the region of the transition point (20) on the other.

6. Metal section according to Claim 5, characterised in that the bending flanges (5), which delimit the connecting cross-piece (3), are aligned running obliquely toward each other at least on the rear side (8) of the cross-piece - when the section is viewed in cross-section.

7. Metal section according to Claim 5 or 6, characterised in that the section has a V-shaped outline at least on the inner side of the channel in the region of the transition point (20) between the connecting cross-piece (3) and the delimiting bending flanges.

8. Metal section according to Claim 5, 6 or 7, characterised in that the bending flanges (5) in each case have a, say, V-shaped cross-section, one shank (6) of which terminates at the respective metal section part (1, 2), and the other shank (7) of which is connected with the connecting cross-piece (3) in the region between the apex and the free end, whereby a partial length of the free end projects over the rear surface (8) of the connecting cross-piece (3).

9. Metal section according to Claim 8, characterised in that the wall thickness of the shank (7), connected with the connecting cross-piece (3), is less in the region (9) of the apex than in the remaining regions.

10. Metal section according to one of Claims 7 to 9, characterised in that the shank (6) of the bending flange (5) which is connected with the metal section parts (1, 2), is connected therewith through a holding cross-piece (4), which is aligned, say, at right-angles to the bending flange (5), whereby the apex of the V-shaped cross-section of the bending flange (5) projects over the surface of the connecting cross-piece (3) towards the inner side of the channel.

11. Metal section according to one of Claims 5 to 10, characterised in that the two metal section parts (1, 2) in their marginal region defining the channel (11) have in each case in a manner known per se a flange (12) which projects over the channel opening, and that in each case the free rim of the flange (12) is provided in its longitudinal direction with a plurality of projections (14) which are bent in the manner of claws toward the base of the channel.

12. Metal section according to one of Claims 5 to 11, characterised in that guide means are provided, running in the longitudinal direction of the section, for a tool for the deformation of the bending flanges (5).

13. Metal section according to Claim 12, characterised by an inserted guide rail for the deformation tool.

14. Metal section according to one of Claims 5 to 12, characterised in that the rear surface (8) of the connecting cross-piece (3) is provided with at least one guide means, running in the longitudinal direction, for the deformation tool.

15. Metal section according to Claim 14, characterised in that the guide means on the connecting cross-piece (3) is constructed as a guiding projection (16) of the cross-piece shape.

16. Metal section according to Claim 14, characterised in that the guide means on the cross-piece (3) is constructed as a groove.

17. Metal section according to Claims 14 and 15, characterised in that the guiding projection (16') has a T-shaped cross-section.

18. Metal section according to one of Claims 5 to 17, characterised in that the surface of the connecting cross-piece (3) forming the base of the channel is provided with a projection running in the longitudinal direction of the cross-piece, preferably running in the centre of the channel.

19. Metal section according to one of Claims 5 to 18, characterised in that the metal section parts (1, 2) are connected with each other by two connecting cross-pieces (3) running at a distance from and parallel to each other, so that there are two outwardly open channels (11).

20. Separating tool to carry out the method according to Claims 1 to 4 on a metal section according to Claims 5 to 19, with a drawing element, on which a tool head is arranged, characterised in that the tool head (26) (in relation to the direction of travel (27)) has a front guiding part (28) for support against the unseparated section and has a deformation part (29) which widens in a wedge shape toward the rear toll end and engages on the bending flanges (5).

21. Separating tool according to Claim 20, characterised in that on the surfaces of the tool head (26) which face the connecting cross-piece (3) which is to be separated out, a longitudinal groove (22) is arranged to receive a guiding projection (16) on the connecting cross-piece (3), or a guiding rail which is inserted into the section.

22. Separating tool according to Claim 21, characterised in that the longitudinal groove is constructed as a hammer-head groove, in which the distance of the part of the groove forming the hammer-head part to the surface of the tool facing the cross-piece (in relation to the direction of travel) is greater at a distance behind the forming part.

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