EP2546449A1

EP2546449A1 - Improved profile assembly and method for mounting such a profile assembly

Info

Publication number: EP2546449A1
Application number: EP12172985A
Authority: EP
Inventors: Frans José Antoine Demasure
Original assignee: Demasure Systems NV
Current assignee: Demasure Systems NV
Priority date: 2011-07-13
Filing date: 2012-06-21
Publication date: 2013-01-16
Anticipated expiration: 2032-06-21
Also published as: BE1019312A3; EP2546449B1

Abstract

Profile assembly comprising a first and a second profile and a spacer with good thermally insulating properties which is adapted to extend between the first and the second profile, and has an upper wall and a first side wall, wherein the first profile is provided with a chamber with a first chamber wall, a second chamber wall and an open side therebetween which adjoins the first side wall of the spacer, wherein the first chamber wall is formed with a first clamping flange adapted to engage against the upper wall and with a second clamping flange which is bendable against the first side wall.

Description

The present invention relates to a profile assembly comprising a first profile and a second profile between which a thermally insulating spacer is received, particularly for use in window, door, veranda or outside wall applications, wherein the profile assembly is typically provided between two spaces in which different temperatures prevail. The invention further relates to a profile for use in such an assembly, to an alley structure for use in such an assembly and to a method for mounting such an assembly.
The present invention has for its object to provide an improved profile assembly of the above stated type which provides better thermal insulation and is at the same time sufficiently strong. The invention more particularly has the object of providing a profile assembly with better thermally insulating properties than those of prior art profile assemblies of similar dimensions. According to advantageous embodiments, the height of the spacer can be easily varied.
The profile assembly according to the invention is distinguished for this purpose in that the first profile is provided with a chamber with a first chamber wall, a second chamber wall and an open side between the first and the second chamber walls. The open side is intended to adjoin a first side wall of the insulating spacer. The first and the second chamber walls typically extend over the full length of the first profile. The first chamber wall is formed with a first clamping flange which typically extends over the full length of the first profile and is adapted to engage against the upper wall of the spacer. The first chamber wall is further formed with a second clamping flange which typically extends over the full length of the first profile and which is bendable against the first side wall of the spacer. The second chamber wall can be provided in similar manner with a first clamping flange which is adapted to engage against a lower wall of the spacer adjoining the first side wall and with a second clamping flange which is bendable against the first side wall of the spacer. Note however that it is also possible to provide this second chamber wall with a profiling into which the spacer can snap or slide. Although only the first profile has been detailed above, the skilled person will appreciate that the second profile can be formed in similar manner for the purpose of co-action with a second side wall of the insulating spacer.
Note that the upper wall and lower wall do not have to be flat or horizontal walls, but refer to a wall adjoining the first side wall respectively at the top and at the bottom. Nor does the first side wall have to be a flat wall, and it can have corners. The skilled person will further appreciate that, in the mounted position of the assembly, the assembly can be situated in a tilted or reversed position in which the upper wall lies at the bottom or is oriented obliquely or vertically.
Providing such a chamber in the first profile on the one hand and on the other a first clamping flange and a bendable second clamping flange intended for engagement against a first side wall of the insulating spacer allows the possibility of the insulating spacer being firmly anchored on the first profile by applying a bending means in the chamber for the purpose of bending the second clamping flange. Bending of the second clamping flange will here also ensure a firm fixing of the first clamping flange against the upper wall of the insulating spacer. The open side of the chamber adjoining the insulating spacer further provides for an additional insulation.
According to an advantageous embodiment, the first and the second profile are manufactured from metal, preferably aluminium or an aluminium alloy. The first and second profiles are typically extrusion profiles or profiles formed with another technique, such as pultrusion profiles or roll forming.
According to a preferred embodiment, the upper wall and the lower wall of the spacer are provided with a protruding ridge in the vicinity of the first side wall of the spacer. The first clamping flange of the first and second chamber walls then preferably have a modified hook shape such that this can engage behind the respective protruding ridges on the upper and lower walls of the spacer. The spacer can in this way be connected to the first profile, after which the second clamping flanges can be bent. The protruding ridges preferably extend over the full length of the spacer.
According to a further developed embodiment, the first side wall of the spacer is provided close to the upper wall and close to the lower wall with a protruding ridge. The second clamping flanges of the first and second chamber walls are then preferably adapted to engage behind these protruding ridges. After bending thereof the second clamping flanges can in this way provide for a firm anchoring of the spacer.
According to an advantageous embodiment, the spacer comprises an alley structure of a first thermally insulating material and a volume part of a second thermally insulating material. The first thermally insulating material is typically harder and/or stronger than the second thermally insulating material, wherein the first material is preferably such that it can comply with the applicable standards for metal profiles with a thermal barrier, for instance the European standard EN 14024. The properties of the material of the alley structure will be particularly relevant for the tensile strength test and the shear strength test described in EN 14024. Determined tests in EN 14024 are further performed in a temperature range between about -20 to 80 degrees Celsius, and the first and second materials must therefore preferably be sufficiently strong mechanically at these temperatures. Note that it is also possible for the spacer to be manufactured in one piece, for instance from a thermally insulating ceramic material or from HDPU. It is also possible to provide an alley structure alone without volume part. This can for instance be a multi-wall alley structure.
The alley structure is preferably provided along at least a portion of the periphery of the volume part and is adapted to co-act with the first and second clamping flanges. The alley structure preferably extends over substantially the whole upper wall and lower wall of the spacer. In addition, the alley structure preferably also extends over at least a portion of the first and/or second side wall of the spacer, and in particular close to the upper wall and lower wall thereof. The volume part can in this way be positioned in a practical manner in the alley structure. Prior to bending of the clamping flange adhesive can further be applied to an outer side of the alley structure facing toward the clamping flange or to an inner side of the clamping flange. The parts of the alley structure located along the first and/or second side walls thus have the advantage of providing for a larger adhesive area.
According to a preferred embodiment, the alley structure comprises an upper alley extending over the upper wall of the spacer and a lower alley extending over the lower wall of the spacer, wherein the volume part is received between the lower and the upper alley. This embodiment has the advantage that the height of the spacer can be easily changed by changing the height of the volume part. According to another variant, the alley structure consists of a tubular alley element in which the volume part is received.
The alley structure is preferably manufactured from a thermoplastic copolymer, for instance ABS. The alley structure could however also be manufactured from a synthetic resin material, (glass fibre-filled) polyamide, polyurethane resins, a ceramic material, a rubber or a combination thereof. The alley structure can for instance be manufactured by extrusion or co-extrusion.
The volume part is preferably manufactured from a hard foam material such as a PUR foam, a phenol foam, a PE foam, a PS foam or a PIR foam.
According to an aspect of the present invention, the chamber is provided with a support means for supporting a mandrel to be moved through the chamber for the purpose of bending the or each second clamping flange.
According to an aspect of the present invention, the chamber has a bottom between the first and the second chamber walls and the support means is formed by the bottom.
According to an aspect of the present invention, the first and/or the second clamping flange is provided with a toothing on an inner side intended to engage against the spacer.
According to an aspect of the present invention, the first and/or the second clamping flange is provided with an adhesive layer on an inner side intended to engage against the spacer; and/or the spacer is provided with an adhesive layer on an outer side intended to engage against the first and/or second clamping flange.
The present invention further relates to a profile for use in an embodiment of a profile assembly as described above. This profile can have one or more of the measures described above for the first profile. The invention also relates to an alley structure for use in an embodiment of a profile assembly as described above. The alley structure can have one or more of the above described measures.
Finally, the invention relates to a method for mounting an insulating spacer between a first and a second profile. The spacer is placed in the longitudinal direction between the first and the second profile. The first profile is provided with a chamber with a first and second chamber wall extending in the longitudinal direction thereof and an open side between the first and second chamber walls. The first profile is placed with its open side against the first side wall of the spacer. The first chamber wall is formed with a first clamping flange arranged over the upper wall of the spacer. The first chamber wall is further formed with a second clamping flange which is bent against the first side wall of the spacer. In similar manner the second chamber wall can be formed with a first and a second clamping flange, wherein the first clamping flange is arranged over the lower wall of the spacer and the second clamping flange is also bent against the first side wall of the spacer. The connection of the second profile to the spacer can take place in similar manner on the second side wall of the spacer.
According to an advantageous embodiment of the method according to the invention, bending of the second clamping flanges is performed by moving a mandrel through the chamber of the first profile. The second clamping flanges of the second profile can be bent in similar manner by moving a mandrel through the chamber of the second profile.
The present invention will be further elucidated on the basis of a number of by no means limitative exemplary embodiments of a profile assembly, a profile and an alley structure for use in such an assembly, and of a method according to the invention with reference to the accompanying drawings, in which:

Figure 1 is a perspective view of a first embodiment of a profile assembly according to the invention; wherein figures 1A and 1B show detail views of the second chamber wall of the first and second profile thereof;
Figures 2A, 2B and 2C show respective cross-sections of the profile assembly of figure 1 in three successive steps during bending of the second clamping flange of the profiles;
Figure 3 is a perspective view of a second embodiment of a profile according to the invention; wherein figure 3A shows a detail view of a chamber wall thereof;
Figure 4 shows a cross-section of a third embodiment of an insulating spacer;
Figures 5A, 5B and 5C show respectively a perspective view, a side view and a top view of a first embodiment of a mandrel according to the invention;
Figures 6 and 7 show two other exemplary embodiments of profile assemblies according to the invention.

The same reference numerals will be used below to refer to identical or similar components of the different embodiments of the profile assembly according to the invention.
A first embodiment of the profile assembly according to the invention will be described in detail with reference to figures 1, 1A, 1B and 2A-2C. The profile assembly comprises a first elongate profile 1 and a second elongate profile 2. These are typically extrusion profiles manufactured for instance from aluminium or an aluminium alloy. In order to thermally insulate first profile 1 from second profile 2 an insulating spacer 3a, 3b, 4 is arranged between these profiles. This spacer 3a, 3b, 4 extends over the full length of the first and second profiles 1, 2 and thus forms a high thermal resistance between the first profile and the second profile. The first and second profiles can for instance be used in window, door, veranda or outside wall applications, wherein the profile assembly is typically used between spaces where different temperatures prevail.
The insulating spacer 3a, 3b, 4 comprises in the first embodiment an alley structure 3 of a mechanically strong thermally insulating material and a volume part 4, also referred to as insulating mass or insulation core, of a less strong thermally insulating material. Mechanically strong is particularly understood to mean a material which allows compliance with the above stated European standard EN 14024. Alley structure 3 consists here of an upper alley 3a and a lower alley 3b. Alley structure 3 can for instance be manufactured from a thermoplastic copolymer such as an ABS material, but also from other materials such as any of the above stated materials for the alley structure. Volume part 4 can for instance be manufactured from a hard foam material such as PUR foam, PIR foam, PS foam, PE foam, phenol foam.
First profile 1 and second profile 2 are each provided with a chamber 9 extending over the full length of profiles 1, 2. Each chamber 9 has a first chamber wall 11, a second chamber wall 12, a bottom 13 and an open side 14. Open side 14 is situated between the first chamber wall 11 and the second chamber wall 12 and adjoins the insulating spacer 3a, 3b, 4. Each chamber wall 11, 12 of first profile 1 is provided with a first clamping flange 5 and a second clamping flange 6. For the second profile only the first chamber wall 11 is provided with a first and second clamping flange 5, 6. The first clamping flange 5 of the first chamber wall 11 is intended to engage against the upper side of upper alley 3a, and the second clamping flange 6 of chamber wall 11 is intended to engage close to the upper side against a side wall of the insulating spacer 3a, 3b, 4. In similar manner the first clamping flange 5 of the second chamber wall 12 is intended to engage against lower alley 3b, and the second clamping flange 6 of chamber wall 12 is intended to engage close to the underside against the side wall of the insulating spacer 3a, 3b, 4. Note that the second chamber wall 12 of second profile 2 is not provided in the illustrated embodiment with a bendable clamping flange but with a profiling 15 into which a side of a lower alley 3b of the spacer can snap or slide.
For the purpose of mounting the profile assembly of figure 1 the volume part 4 is first arranged between upper alley 3a and lower alley 3b. The thus formed insulating spacer is then arranged between first profile 1 and second profile 2, wherein the first clamping flanges 5 engage against alley structure 3a, 3b, see figure 2A. The second clamping flanges are then bent, see figures 2B and 2C. This bending is typically performed by moving a mandrel through chambers 9 of first profile 1 and second profile 2, but could also take place with another bending means.
The upper side 23 of upper alley 3a is provided in each case close to both longitudinal edges with a protruding ridge 7 intended for co-action with a first clamping flange 5 of respectively the first and the second profile 1, 2. In the embodiment illustrated in figure 1 the first clamping flanges 5 are substantially hook-like and adapted to engage behind a protruding ridge 7. The underside 24 of lower alley 3b is provided in similar manner with protruding ridges 7 which co-act with the lower hook-like clamping flanges 5. The insulating spacer 3a, 3b, 4 can in this way be slid or snapped into profiles 1, 2, after which the second clamping flanges 6 can be bent. Side walls 21, 22 of the insulating spacer are further provided in each case, close to upper wall 23 and close to underside 24, with an outward protruding ridge 8. The second clamping flanges 6 are formed so that, after bending, they engage behind these protruding ridges 8.
Figures 2B and 2C illustrate the bending process. In a first step the second clamping flange 6 engages behind the protruding ridge 8, see figure 2B, and clamping flange 6 is subsequently bent further so as to fit against side walls 21, 22 of insulating spacer 3a, 3b, 4, see figure 2C. The second clamping flange 6 is formed for this purpose with a first part 31 protruding in the direction of the spacer and a second part 33 protruding in the direction of the spacer. First part 31 is intended for the purpose of engaging over the protruding ridge 8. Upper alley 3a is provided at its longitudinal edges with a downward protruding wall part 33. Lower alley 3b is provided in similar manner at its longitudinal edges with an upward protruding wall part 34. The second protruding parts 32 of the second clamping flange 6 are intended to engage below the downward/upward protruding wall parts 33, 34. A firm anchoring of spacer 3a, 3b, 4 is in this way obtained in profiles 1, 2.
The skilled person will appreciate that both the profiles and the alley structure can be provided with additional profiling (for instance flanges 36) for other purposes.
In order to further improve this anchoring, the end edge 35 of the first clamping flange 5 can be provided over the full length with a toothing 45, see figure 3A. The second clamping flange 6 can also be provided with a toothing 46 over the full length in the longitudinal direction, and in particular on and/or close to the protruding part 31. According to a variant hereof, clamping flanges 5, 6 can be provided only at a number of locations with a toothing. Adhesive can further be applied to the inner side of clamping flanges 5, 6 so as to further improve the adhesion to the spacer.
For the profiles of figures 1 and 3 the height h of volume part 4, and thus also the height of chambers 9, can be varied in accordance with the desired height. The bottom 13 of chamber 9 of a profile 1 can further be provided with two guide ribs 10a, 10b protruding into chamber 9. These guide ribs 10 are intended for the purpose of guiding a mandrel on bottom 13 between the first chamber wall 11 and guide rib 10a and between the second chamber wall 12 and guide rib 10b. Providing such guide ribs 10a, 10b makes it possible to use the same mandrel to bend the second clamping flanges 6 for profile assemblies having a differing distance d, see figure 1, and so a differing height h.
Figure 4 illustrates a third embodiment of an insulating spacer 3, 4 according to the invention. In this third embodiment alley structure 3 consists of a hollow tube in which an optionally softer insulating material is arranged. This insulating material can for instance be injected or be slid in. The hollow tube can be provided, as described for the first and second embodiment, with a first protruding ridge 7 intended for co-action with a first clamping flange and a second protruding ridge 8 intended for co-action with a second clamping flange. Compared to the first and second embodiments, the variant of figure 4 has the drawback that the height of the insulating spacer 3, 4 is less easy to modify. According to a variant, the alley structure can comprise additional internal walls (see the broken lines in figure 4).
Finally, figures 5A, B and C illustrate an embodiment of a mandrel according to the invention intended for the purpose of bending a second clamping flange. Mandrel 50 has a front end 51 and a rear end 52. Such a mandrel 50 is intended to be pulled through a chamber 9 of a profile, wherein front end 51 is first inserted into chamber 9. Mandrel 50 is provided with a number of first wheels 53a which are mounted such that the height of their upper running surface gradually increases from front end 51 to rear end 52. Further provided is a set of second wheels 53b intended for the purpose of making contact with wall 13 of chamber 9. Front end 51 can further be provided with a wedge-like element. The embodiment illustrated in figure 5 is a single mandrel intended for the purpose of bending one second clamping flange 6. The skilled person will appreciate that it is also possible to use a dual variant intended for the purpose of simultaneously bending a second clamping flange 6 of a first chamber wall and of a second chamber wall. The skilled person will appreciate that other variants of mandrel can also be used in the present invention, for instance in accordance with the height of the profiles and the design of the second clamping flange 6.
Figures 6 and 7 further show two other possible variants of a profile assembly according to the invention, wherein similar components are designated with the same reference numerals. Note that the lower wall of the spacer (lower alley 3b) is oriented obliquely in the variant of figure 6 and oriented vertically in the variant of figure 7. The first and second side walls of the spacer further have an angle.
The present invention is not limited to the above described embodiments, and the skilled person will appreciate that many modifications and variants can be envisaged within the scope of the present invention, which is defined solely by the following claims.

Claims

Profile assembly comprising an elongate first profile and second profile (1, 2) with a longitudinal direction and a spacer (3,3a,3b;4) with good thermally insulating properties, which spacer is adapted to extend in the longitudinal direction between the first and the second profile, the spacer having an upper wall (23) and a first side wall (21) adjoining the upper wall,
characterized in that
the first profile is provided with a chamber (9) with a first chamber wall (11), a second chamber wall (12) and an open side (14) between the first and the second chamber walls, which open side adjoins the first side wall of the spacer, wherein the first and the second chamber walls extend in the longitudinal direction, and that the first chamber wall is formed in the longitudinal direction with a first clamping flange (5) adapted to engage against the upper wall of the spacer and with a second clamping flange (6) which is bendable against the first side wall of the spacer.
Profile assembly as claimed in claim 1, characterized in that the second chamber wall (12) is provided in the longitudinal direction with a first clamping flange adapted to engage against a lower wall of the spacer adjoining the first side wall and with a second clamping flange which is bendable against the first side wall of the spacer.
Profile assembly as claimed in claim 1 or 2, characterized in that the first and second profile are manufactured from metal, preferably aluminium or an aluminium alloy.
Profile assembly as claimed in any of the foregoing claims, characterized in that the upper wall of the spacer is provided with a protruding ridge (7) and that the first clamping flange (5) of the first chamber wall is hook-shaped and adapted to engage behind the protruding ridge.
Profile assembly as claimed in any of the foregoing claims, characterized in that the lower wall of the spacer is provided with a protruding ridge (7) and that the first clamping flange (5) of the second chamber wall is hook-shaped and adapted to engage behind the protruding ridge.
Profile assembly as claimed in claim 4 or 5, characterized in that the protruding ridge (7) extends in the longitudinal direction close to the first side wall of the spacer, preferably over the full length of the spacer.
Profile assembly as claimed in any of the foregoing claims, characterized in that the first side wall of the spacer is provided close to the upper wall and/or close to the lower wall thereof with a protruding ridge (8), and that the second clamping flange (6) of the first and/or second chamber wall is adapted to engage behind the respective protruding ridge.
Profile assembly as claimed in any of the foregoing claims, characterized in that the spacer comprises an alley structure (3) of a first thermally insulating material and a volume part (4) of a second thermally insulating material, which alley structure is adapted to co-act with the first and the second clamping flange, wherein the first thermally insulating material is mechanically stronger than the second thermally insulating material.
Profile assembly as claimed in claim 8, characterized in that the alley structure is provided along the periphery of the volume part; and/or that the alley structure extends at least along the upper and lower wall of the spacer.
Profile assembly as claimed in claim 7 and either of the claims 8-9, characterized in that the alley structure is provided with the respective protruding ridge(s) (8) and that the second clumping flange (6) of the first chamber wall and/or of the second chamber wall is adapted, after bending, to clamp against the respective protruding ridge (8); and/or that the alley structure has a first longitudinal edge adjoining the first and/or second clamping flange of the first chamber wall and that the alley structure is provided at this first longitudinal edge with a downward protruding wall part (33) intended to fit against the volume part; and/or that the alley structure has a second longitudinal edge adjoining the first and second clamping flange of the second chamber wall and that the alley structure is provided at this second longitude edge with an upward protruding wall part (34) intended to fit against the volume part.
Profile assembly as claimed in any of the claims 9-10, characterized in that the alley structure comprises an upper alley (3a) and a lower alley (3b), wherein the volume part (4) is received between the lower and the upper alley.
Profile for use in an assembly as claimed in any of the foregoing claims, which profile is provided with a chamber (9) with a first chamber wall (11), a second chamber wall (12) and an open side (14) between the first and the second chamber walls, which open side adjoins the first side wall of the spacer, wherein the first and the second chamber wall extend in the longitudinal direction, wherein the first chamber wall is provided in the longitudinal direction with a first clamping flange (5) adapted to engage against the upper wall of the spacer and with a second clamping flange (6) which is bendable against the first side wall of the spacer.
Alley structure (3) for use in a profile assembly as claimed in any of the claims 9-11, which alley structure is manufactured from a thermally insulating material and adapted to co-act with the first and the second clamping flange (5, 6) of the first chamber wall.
Method for mounting a spacer with good thermally insulating properties between an elongate first and second profile (1, 2) with a longitudinal direction, which spacer is placed in the longitudinal direction between the first and the second profile, which spacer has an upper wall (23) and a first side wall (21) adjoining the upper wall, characterized in that
the first profile is provided with a chamber (9) with a first and second chamber wall (11, 12) extending in the longitudinal direction and an open side (14) between the first and the second chamber wall; the first profile is placed with its open side against the first side wall of the spacer; and the first chamber wall (11) is formed in the longitudinal direction with a first clamping flange placed over the upper wall of the spacer and with a second clamping flange which is bent against the first side wall of the spacer.
Method as claimed in claim 14, characterized in that bending of the second clamping flange is performed by moving a mandrel through the chamber.