EP2386708A1

EP2386708A1 - Composite profile for the frame of a window, door or similar

Info

Publication number: EP2386708A1
Application number: EP11003558A
Authority: EP
Inventors: Els Fonteyne
Original assignee: Reynaers Aluminium NV
Current assignee: Reynaers Aluminium NV
Priority date: 2010-05-11
Filing date: 2011-05-02
Publication date: 2011-11-16
Also published as: BE1019333A3

Abstract

Composite profile for the frame of a window, door or similar, with an outer shell (2) and inner shell (3) connected by an insulating course (5), whereby a foam strip (25) is applied in a chamber (19) of the insulating course (5) with a memory of the original shape in which it was produced, whereby this foam strip (25) is compressed into a more compact form before insertion that is fixed at a lower temperature, and which allows the foam strip (25) to slide in the aforementioned chamber (19) and then the foam strip (25) is expanded to its original shape whose dimensions are chosen such that upon expansion the foam strip (25) is wedged in the aforementioned chamber (19).

Description

The present invention relates to a composite profile for the frame of a window, door or similar.
Composite profiles with a metal outer shell and inner shell, for example in aluminium, that are connected by a thermal bridge have long been known.
The aforementioned thermal bridge can thereby contain one or more insulating courses that are constructed as 'multichamber profiles', for example.
Such a multichamber profile contains a number of hollow chambers separated from one another by walls, all such that the flow of cold is reduced.
In order to further improve the thermal insulation properties of such a chamber, it is known to apply additional insulating foam between the inner shell and outer shell.
It is thus possible during production of the frame to slide a strip of insulating foam into a chamber of the insulating course.
A disadvantage is that this manually slid-in strip is not wedged in the profile and thus easily comes loose during further operations and handling of the profile and can fall out.
Insulating foams are also known that are cast onto a wall of an insulating course and which are foamed up in a subsequent production stage.
A disadvantage of such foams is that they cannot be used in insulating courses with chambers as the foam material can only be applied to the outer periphery of the insulating course.
Another disadvantage is that such foams cannot be painted and are difficult to apply in a controlled way.
In order to obtain a painted frame it is known that the separate outer and inner shell are first given a coat of paint before affixing the foam.
This additional process stage results in a longer and consequently more expensive production cost of the frame.
The purpose of the present invention is to provide a solution to one or more of the aforementioned disadvantages and/or other disadvantages by providing a composite profile for the frame of a window, door or similar, whereby the composite profile contains an outer shell and inner shell that are connected together by means of at least one insulating course, whereby an additional foam strip is applied in at least one chamber of the insulating course, whereby this foam strip has a memory of the original shape in which it was produced, whereby this foam strip is compressed into a more compact form before insertion and this form is fixed at a lower temperature, and this more compact form allows the foam strip to slide in the aforementioned chamber and then the foam strip is expanded to its original shape whose dimensions are chosen such that upon expansion the foam strip is wedged in the aforementioned chamber.
An advantage is that the presence of the foam strip substantially improves the insulation value of the composite profile.
Another advantage is that the foam strip is wedged in the profile and thus cannot come loose in successive operations and handling of the profile.
To this end the dimensions of the more compact form of the foam strip are preferably smaller than the dimensions of the chamber in at least one direction, and the dimensions of the original shape of the foam strip are greater than or equal to the dimensions of the chamber in at least one direction.
An advantage is that the foam strip is easy to insert in the chamber and that after expansion the foam strip is wedged in the chamber.
This wedging of the foam strip not only means wedging between the walls of the chamber, but also wedging between ribs provided in these walls to this end.
The aforementioned wedging does not necessarily need to imply that the entire space in the chamber is occupied by the expanded foam strip.
The present invention also relates to a method for insulating a composite profile of the aforementioned type, whereby the method comprises at least the steps of:

the provision of a foam strip
the compression of the original shape of this foam strip into a more compact form with dimensions that enable the foam strip to be slid into a chamber of the profile.
the fixing of this more compact form by lowering the temperature
the insertion of the thus obtained more compact form of the foam strip into the chamber concerned.
the heating of the foam strip in order to enable it to expand to its original shape, which is chosen to be greater than the chamber concerned in at least one direction, so that upon expansion the foam strip is wedged in the chamber.

An advantage is that this method is very simple to apply.
Another advantage is that the foam strip will not come loose during sawing or other operations or handling of the profile, as the foam strip is wedged in place.
Another additional advantage is that the outer and inner shell can be painted after the profile has been assembled, such that both the outer and inner shell can be painted in one single production step.
Preferably the composite profile contains extruded insulating courses and the heat of extrusion of the insulating courses is used to heat the foam strip in the chamber to allow this foam strip to expand.
An advantage is that a separate heating step is not required during production of the composite profile, which of course saves time and energy and thus also contributes to the cheap, simple and efficient production of the composite frame.
With the intention of better showing the characteristics of the invention, a preferred embodiment is described hereinafter by way of an example, without any limiting nature, of a composite profile according to the invention, with reference to the accompanying drawings, wherein:

figure 1 schematically shows a cross-section of a composite profile according to the invention in which the foam strip has been put in a more compact form.
figure 2 shows the profile of figure 1 in the expanded state of the foam strip.
figure 3 shows an alternative embodiment of figure 1.
figure 4 shows the profile of figure 3 in the expanded state of the foam strip.

Figure 1 schematically shows a first embodiment of a composite profile 1 according to the invention.
Such a composite profile 1 is primarily built up from an outer shell 2 and an inner shell 3, preferably of aluminium, but other materials are not excluded according to the invention.
Furthermore the composite profile 1 has a thermal bridge 4 in the form of one or more insulating courses 5, that form a link between the aforementioned outer shell and inner shell 2-3.
In the profile 1 of figure 1, both the outer shell and inner shell 2-3 are constructed in the form of hollow tubular profiles 6-7 with an outer chamber 8 and an inner chamber 9 respectively.
The aforementioned outer chamber 8 is bordered by two pairs of parallel walls 10-13 of the outer shell 2, respectively by two longitudinal walls 10-11 and two transverse walls 12-13.
In the embodiment shown, the inner shell 3 is similarly bordered by two longitudinal walls 14-15 that are connected by two transverse walls 16-17.
In figure 1 the thermal bridge 4 between the outer shell and inner shell 2-3 is constructed in the form of an insulating course 5, more specifically in the form of a hollow tubular profile 18 with two chambers 19 that are completely separated from one another by a partition 20 in order to restrict the flow of cold from the outside to the inside as much as possible.
The insulating course 5 is preferably manufactured from plastic or another thermal insulation material and forms a link between the outer shell 2 and inner shell 3.
In the embodiment shown the longitudinal edges 21 of the insulating course 5 have widened ends 22, and the longitudinal walls 10,14, which are aligned to one another, of the outer chamber and inner chamber 8-9 each have grooves 23 in which the aforementioned ends 22 are secured.
Each of these grooves 23 is thereby bordered by two upright ribs 24 whereby the ends are secured in these grooves, for example by folding one of these ribs inwards.
Although in the embodiment shown, the grooves 23 of the outer shell and inner shell 2-3 are directly opposite one another, this does not strictly necessarily have to be so.
According to the invention, in at least one chamber of the insulating course 5 of the composite profile 1 there is at least one additional foam strip 25.
In figure 1 there are two such foam strips 25, i.e. a foam strip 25 in each chamber 19 of the insulating course 5.
According to the invention the foam strip 25 has a memory of the original shape in which the foam strip 25 was produced.
The foam strip 25 is manufactured from a specific foam such that the foam strip 25 has the property that it can be compressed into a more compact form and this more compact form can be fixed by cooling the foam strip 25.
Preferably the foam strip 25 is deformed such that the dimensions of this more compact form are smaller, in at least one direction, than the dimensions of the chamber 19 in which the foam strip 25 is inserted, as shown in the example of figure 1.
In a practical embodiment the foam strip 25 is manufactured from a foam that again takes on its original shape at a higher temperature, for example at a temperature above 50°, and preferably the aforementioned more compact form of the foam is stable at normal ambient temperatures.
In the most practical embodiment the foam strip 25 is made from a polyurethane foam (PU foam).
Preferably the foam strip 25 is made from a foam with a high filling capacity and sufficient elasticity, in order to fill the chamber 19 of the composite profile 1 as completely as possible.
Of course a material with high shape stability is preferably chosen so that there is no shrinkage in the course of time.
It will be clear to a man skilled in the art that this more compact form is of course beneficial for inserting the foam strip 25 in the chamber 19 of the insulating course 5, and that the foam strip 25 can be easily slid in lengthways in this more compact form from an open crosscut end of the insulating course 5. The foam strip 25 must be sufficiently stiff in its more compact form for this purpose.
The material properties of the foam strip 25 ensure that upon heating of the foam strip 25 it again evolves into its original shape or takes on this original shape again.
Preferably the original shape is chosen such that it is greater than or equal to the dimensions of the chamber 19 in which the foam strip 25 is inserted, at least in one direction.
In the composite profile 1 of figure 2 the foam strip 25 is expanded such that the aforementioned chamber 19 is completely filled by the expanded foam strip 25, all such that the flow of cold from the outside to the inside is counteracted as much as possible.
According to the invention the shape and dimensions of the foam strip 25 are chosen such that upon expansion of the foam strip 25, the foam strip 25 is wedged in a chamber 19 of the composite profile 1.
The method for insulating a composite profile according to the invention is very simple and as follows.
Prior to inserting the foam strip 25 in the composite profile 1, the foam strip 25 is heated to a certain temperature such that the foam strip 25 can be easily deformed.
The foam strip 25 is thereby compressed, and preferably the foam strip 25 is deformed such that the foam strip 25 has smaller dimensions in at least one direction.
Starting from a beam-shaped foam strip 25 with a width A and height B, a more compact form can be obtained during the deformation of the foam strip 25, whereby one dimension of the beam has been substantially reduced, for example by a factor of 5 or more.
For example a beam with a height B of 11.5 millimetres and a width A of 38.8 millimetres can be reduced to a beam with a height B of 1.5 millimetres and width A of 34.8 millimetres.
According to the invention this more compact form is fixed at a lower temperature.
Starting with a composite profile 1 with an outer shell and inner shell 2-3 connected by a thermal bridge 4, the foam strip 25 can be easily inserted in this more compact form into the chamber concerned 19 of the insulating course 5.
In a subsequent stage of the method according to the invention, the foam strip 25 is heated up in order to enable this foam strip 25 to expand to its original shape, the dimensions of which have been chosen such that the foam strip has greater dimensions than the chamber 19 in at least one direction, so that upon expansion of the foam strip 25, the foam strip 25 is wedged in the chamber 19.
To do this heating it is preferable to make use of the temperature increase that occurs after the extrusion process of the insulating courses 5, all such that no extra energy is required to expand the foam strip 25.
In the above-mentioned numerical example, by heating the more compact form it can change to a larger beam shape with a width of 36.4 millimetres and a height of 9.6 millimetres, for example.
It is clear that for wedging the foam strip 25 in the chamber 19, the least one of the dimensions A or B must be equal or practically equal to the dimension of the chamber 19.
It will be clear to a man skilled in the art that the material of the foam strip 25 is resistant to the typical temperatures that occur during painting of the composite profile 1.
Moreover, by wedging the foam strip 25 in a chamber 19 of the composite profile 1 there is no risk of the foam strip 25 coming out of the insulating course 5 during subsequent operations on the composite profile 1.
Figure 3 shows a variant that is primarily different from figure 1 in that the thermal bridge 4 consists of a number of insulating courses 5.
In the example shown there are two identical insulating courses 5 that are a mirror image of one another, located at a certain distance from one another, but it is also possible to provide more insulating courses, with different shapes or otherwise.
In this embodiment the sides 26, that are aligned to one another, of the insulating courses 5 have two ribs 27 with edges folded back at right angles 28.
In contrast to the previous embodiment of figure 1 there is no fully closed chamber 19 in the insulating course 5, but the chamber 19 is bordered by a wall 26 of the insulating course 5 and by the aforementioned ribs 27 on the insulating course 5.
In the variant of figure 3 the chamber 19 is not closed and there is a clear space between the end points of the edges folded towards one another 28.
In this variant it is possible, for example, that upon expansion the foam strip 25 is sturdily wedged in between the end points of the folded edges 28.
However, it is also possible that the foam strip 25 is wedged between the wall 26 of the insulating course 5 and the folded edge 28.
The method for insulating a composite profile 1 according to the invention is similar, whereby the foam strips 25 can be easily inserted between the ribs 27 in their more compact form, for example by sliding lengthwise.
After expansion of the foam strip 25, the method according to the invention results in the composite profile 1 shown in figure 4.
As shown in figure 4, in this expanded state the foam strips 25 have dimensions such that the foam strips 25 are mainly wedged in by the ribs 27.
According to a variant not shown, it is also possible for the foam strips 25 to mutually wedge one another, provided that the foam strips expand during expansion such that they come into contact with one another. This mutual wedging is not a strict requirement of the invention, however.
In contrast to figures 1 and 2, the foam strips 25 in figure 4 are expanded anisotropically, such that as a result of the expansion, the material of the foam strip 25 extends beyond the folded ribs 27 and expands into the free space behind the ribs 27.
Although in the example shown in figure 4, a free space between the expanded foam strips 25 can be seen, it is not excluded that the expanded foam strips 25 expand such that they touch one another.
The shape in the expanded state is determined by the original shape of the foam strip 25, and consequently the wedging of the foam strip 25 in the chamber 19 can also be realised by choosing the original shape of the foam strip 25 to be practically equal to or greater than the space between the ribs 27 in at least one direction.
In the embodiment shown, both expanded foam strips are kept in their place by the walls 28 and are thus wedged in the chamber 19.
In a variant not shown it is also possible that only one of the two insulating courses 5 has ribs 27 and that only one foam strip 25 is placed between the ribs 27, which is expanded to such a shape that the periphery of the expanded shape extends to against the other insulating course 5, for example.
It is also possible that in this case the foam strip 25 only partially fills the chamber 19, and subject to the choice of the appropriate original shape, is only wedged by the ribs 27.
It is clear that the chamber 19 in which the foam strip 25 is placed can also be partly formed by a wall of the outer shell and/or inner shell.
The present invention is by no means limited to the embodiments described as an example and shown in the drawings, but a composite profile 1 according to the invention and a method for insulating a composite profile 1 can be realised in all kinds of variants, without departing from the scope of the invention.

Claims

Composite profile for the frame of a window, door or similar, whereby the composite profile (1) contains an outer shell (2) and inner shell (3) that are connected together by means of at least one insulating course (5), characterised in that an additional foam strip (25) is applied in at least one chamber (19), closed or otherwise, of the insulating course (5) of the composite profile (1), whereby this foam strip (25) has a memory of the original shape in which it was produced, whereby this foam strip (25) is compressed into a more compact form before insertion and this form is fixed at a lower temperature, and this more compact form allows the foam strip (25) to slide in the aforementioned chamber (19) and then the foam strip (25) is expanded to its original shape whose dimensions are chosen such that upon expansion the foam strip (25) is wedged in the aforementioned chamber (19).
Composite profile according to claim 1, characterised in that a number of foam strips (25) are applied, that are in a number of chambers (19), closed or otherwise.
Composite profile according to claim 1 or 2, characterised in that the insulating course (5) is a tubular profile with at least one hollow chamber (19), closed or otherwise, and that the aforementioned foam strip (25) is placed in such a chamber (19) of the insulating course (5).
Composite profile according to any one of the foregoing claims, characterised in that between the outer shell and inner shell (2-3) there are two insulating courses (5) at a certain distance from one another, and that the aforementioned chamber (19) is formed by a wall (26) of one of the insulating courses (5) on which there are ribs (27) with perpendicularly folded edges (28).
Composite profile according to any one of the foregoing claims, characterised in that the insulating course (5) has two ribs (27) and that the foam strip (25) is placed between the aforementioned ribs (27) in its more compact form.
Composite profile according to any one of the foregoing claims, characterised in that the dimensions of the more compact form are smaller than the dimensions of the chamber (19) in at least one direction, and that the dimensions of the original shape are greater than or equal to the chamber (19) in at least one direction.
Method for insulating a composite profile, whereby the composite profile (1) contains an outer shell and inner shell (2-3) that are connected together by at least one insulating course (5), characterised in that the method comprises at least the steps of:
- the provision of a foam strip (25) that has a memory of the original shape in which the foam strip (25) was produced.

- the compression of the original shape of this foam strip (25) into a more compact form with dimensions that enable the foam strip (25) to be slid into a chamber (19), closed or otherwise, of the insulating course (5) of the composite profile (1) .

- the fixing of this more compact form by lowering the temperature;

- the insertion of the thus obtained more compact form of the foam strip (25) into the chamber (19) concerned; and

- the heating of the foam strip (25) in order to enable it to expand to its original shape, which is chosen to be greater than the chamber (19) concerned in at least one direction, so that upon expansion the foam strip (25) is wedged in the chamber (19), closed or otherwise.
Method according to claim 7, characterised in that the foam strip (25) is manufactured from a foam that adopts its original shape again at a higher temperature.
Method according to claims 7 or 8, characterised in that the more compact form is stable at normal ambient temperatures.
Method according to any one of the claims 7 to 9, characterised in that use is made of the extrusion heat of the insulating courses (5) to heat up the foam strip (25) in the chamber (19) to enable it to expand.