GB2488670A

GB2488670A - Profiled plastic element having chambers containing foam and a stiffening element

Info

Publication number: GB2488670A
Application number: GB1203787.5A
Authority: GB
Inventors: Stefan Diekmann
Original assignee: Porta Bauelemente & Mehr & Co KG GmbH
Current assignee: Porta Bauelemente & Mehr & Co KG GmbH
Priority date: 2011-03-04
Filing date: 2012-03-02
Publication date: 2012-09-05
Anticipated expiration: 2032-03-02
Also published as: PL237554B1; NO346013B1; NO20120239A1; DE102012004107A1; SE540803C2; NL2008406C2; PL398297A1; SE1651116A1; SE1250201A1; CH705044A2; HU230280B1; DK178445B1; CH705044B1; BE1020087A3; GB201203787D0; AT511180B1; HUP1200142A2; FR2972213B1; DK201200168A; AT511180A3

Abstract

A profile element made of plastic, preferably for a window frame profile, casement or other glazing carrier, comprising a plurality of chambers 7 which are completely foamed with a foam material 8 and wherein at least in one of the chambers 7 a stiffening element 9 12 is provided. The foam 8 is preferably polyurethane foam and the stiffening or reinforcement member 9 12 is preferably a C shape or a box shape and made of steel or glass fiber reinforced plastic. The stiffening member 9 12 is preferably embedded in the foaming material 8. There may be outwardly disposed pre-chambers 7b, 11b, 11c that are not filled with foam or only partially filled. The stiffening member may be located in the largest chamber preferably in a vertical extension (the vertical plane) of the glass panes. The foam acts as insulation for the window frame.

Description

Profiled plastic element The invention relates to a profiled plastic element, particularly used as a frame profile and casement or other glazing carriers as well as for window frames or the like, comprising a plurality of chambers.

Window casement or frame profiles which are combined, when mitered, to form general quadrilateral casements or window frames are designed in a chambered manner for stability and insulation reasons, i.e. the cross-section of the profile is subdivided by several bridges into a plurality of chambers which are generally filled with air, so as to avoid needless complications during the manufacturing of the profiles by extrusion.

To improve the strength properties in the region of one or more glass panes (two or three laminated glass panes), a reinforcement or stiffening was already inserted in the region of the pane in one of the larger chambers of the profiled element or profiled casement so as to guarantee window frame stability.

Beyond that it is known to partially make use of stiffening profiles of polyurethane to improve the insulation properties of profiled plastic elements for window profiles (casements or window frames), as the direct foaming of window profile chambers imposes technical problems (see DE 103 5649 Al).

However, to insert polyurethane foam cores in some chambers of a profiled element for manufacturing window or door frames (see AT 410 350 A) causes difficulty in case of larger dimensions of the elements and is also not satisfactory with regard to the attainable heat transfer values. -Accordingly, it is the object of the invention to provide for a profiled plastic element which is, on the one hand, light but suffices, as concerns its heat transfer values, to passive house requirements, but which is, on the other hand, also of high stiffness and mechanical load capacity. It is also the object of the invention to provide for a corresponding casement (casement frame) and a window frame as well as a combination of these as a complete window system.

According to the invention, this object concerning the profiled element is solved by the features of claim 1.

As concerns a casement, a window frame or a combination of casement and window frame, the above-mentioned object is solved by the features of claims 8, 10 and 11.

According to the invention, a profiled plastic element is provided, particularly for casements or other glazing carriers, window frames, door frames etc., which is designed as a multi-chamber profile comprising a plurality of chambers substantially being entirely foamed with a foaming material, particularly polyurethane: at least one of said chambers being provided with a reinforcing or stiffening element. Accordingly, the crucial point is that all chambers of the profiled element are at least substantially entirely foamed and that a stiffening element is used, particularly a hollow steel profile, preferably an open profile, so that said profiled element and, thus, the casement or window frame consisting thereof, is, on the one hand, of very high heat insulation properties and of a heat transfer value Uw c I and is, on the other hand, of sufficient mechanical stability.

Preferably, the stiffening element, particularly a C-shaped or comparable open tee square steel element is entirely embedded into the foaming material.

Preferably, said foaming material, particularly polyurethane, has a processing temperature or exothermal reaction temperature that does not exceed 80 to 90°C.

Preferred embodiments of the invention are set out in the dependent claims.

In the following, the invention will be explained in more detail by means of examples with appertaining illustrations, in which Fig. 1 is a cross-sectional view of a profiled frame of a casement according to an embodiment of the invention: Fig. 2 is a cross-sectional view of a combination of casement and window frame; Figs. 3a-3d are computer simulations relating to the isothermal curve of the combination according to Fig. 2 as well as to another embodiment; Fig. 4 is a cross-sectional view of a combination of a casement and window frame according to another embodiment for heat absorbing outer surfaces, similar to the embodiment of Fig. 2; and Fig. 5 is a cross-sectional view of a combination of casement and window frame according to another embodiment for heat-repelling (reflecting) outer surfaces, similar to the embodiment of Fig. 2.

Fig. I shows a profiled frame P of a casement 1 (see Fig. 2). Said profiled frame P (a glass pane and a glass fixing rail not being shown) consists of a plurality of foamed chambers 7; a stiffening element, particularly a profiled steel element 9, preferably being inserted into the largest chamber 7a.

As concerns the further description of the profiled frame P according to Fig. I it is

referred to the description of Fig. 2 below.

Fig. 2 shows a cross-sectional view of a casement 1 with a laminated glass pane 2 being inserted therein and shown just schematically which is fixed to said casement 1 by means of sealing profiles 3 and a glass fixing rail 4.

In Fig. 2, casement I is shown in combination with a window frame 5 with which said casement 1 is in engagement or in contact under pressure through sealing profiles 6.

The specific feature or peculiarity of profiled frame P (Fig. 1) or of casement I, in the following referred to as casement frame 1 comprising a plurality of chambers 7, is in that all of same, at least a plurality of approx. 75%, are entirely filled or foamed with polyurethane foam 6 used as foaming material, said polyurethane foam 8 foaming chambers 7 of casement frame I preferably directly. It is preferred to have all of chambers 7 entirely foamed in order to achieve the best heat insulation values.

However, "substantially entire foaming of the chambers" is understood to mean 100% of the number of chambers 7 down to approx. 75% of the number of chambers 7.

Another specific feature of casement frame I is in that the largest chamber 7a includes an open profiled steel element 9 as profile stiffening element for casement frame I, said steel element being entirely foamed in said polyurethane foaming material and is supported, if need be, by wall projections of the wall of chamber 7.

Due to the virtually entire foaming of the entire profile cross-section of casement frame 1, same has a passive-house-compliant Uw value of < 0.8 (thermal bridge valueX = 0.3W/m2K).

The profiled steel stiffening 9 serves to enhance the static stiffening of casement frame 1, likewise as protection against burglary and at the same time as isothermal guiding element in said casement frame I in combination with the laminated glass pane 2, as measurements and simulation results have shown (see Figs. 3a-3d).

According to Fig. 1, the window frame 5 is shown in its cross-section, correspondingly also being foamed to at least 75%, but preferably entirely, in an embodiment provided with chambers (chambers 11) with a foaming material, particularly polyurethane foam 8. Here, the largest chamber 13 is preferably also provided, substantially in the vertical extension of the laminated pane as well as the stiffened chamber 7a of the casement frame 1, with a stiffening element 12, preferably a profiled hollow steel component which is also entirely embedded in a foaming material, particularly polyurethane foaming material 8. Here, too, the combination of PUR foaming material 8 with profiled stiffening 12, preferably made of steel or fiber-reinforced plastic °. : material, results, on the one hand, in a particularly high heat-insulation characteristic of window frame 11 and, on the other hand, in a brilliant mechanical stability and protection against burglary or the like. Profiled steel component 12 may, if need be, also be supported against projections 14.

Here, too, the profiled frame of window frame 5 with its chambers 11 is also foamed * with polyurethane on site, with a polyurethane foam of a density from 30 to 40 kg/m3 being preferably used.

Such foam of a X-value of approx. 0.021 to 0.031 allows, in all, to comply with the passive house standards or the standards for low-energy houses of a heat transfer coefficient Uw 0.8.

The invention provides a window and/or frame profile for window or door frames that is of light weight, on the one hand, and of mechanical high strength, on the other hand, and is, beyond that, of a high mechanical stability so that a polyurethane foam of less density with especially high resistance to heat transfer can be used.

It is particularly advantageous to have the glass fixing rail 4 also being foamed with polyurethane foam 8, as is also shown in Fig. 1. Thus, the heat insulation strength can be further improved.

The corresponding computer simulations of the combined window frame/casement frame are shown in Figs. 3a to 3d, the isotherms being marked with 15.

S

Fig. 3a shows an embodiment, with the stiffening profile (steel profile element 9) being inserted only in casement frame I of the casement; chambers 11 of window frame 5 being foamed with a polyurethane foam 5 of X = 0.031 which is also used for the foaming of chambers 7 of casement frame 1. As a whole, an Uf-value of 0.52 W/km2K is reached. In Fig. 3b, the stiffening steel profile element 12 is not only inserted into casement frame I but also into window frame 4. In this connection, when foaming the chambers of profiles I and 4 (casement and frame profiles) with a PUR foam having a ?.-value of 0.031, Uf-values of 0.94 W/m2K are reached.

When using a polyurethane foam having a A.-value of 0.021, the Uf-values as listed in the table below are obtained; the corresponding statements relating to PUR foam with = 0.021 being shown in Figs. 3c and 3d (with and without window frame stiffening).

Uf-value --Uf-value PUfoamX= 0.031 PUfoamX=0.021 Only casement I with steel profile 9 0.82 W/m2K 0.74 Wfm2K Casement I and window frame with steel profile elements 9, 0.94 W/m2K 0.84 W/m2K Thus, a window system consisting of a window frame and a casement can be provided by combining the stiffening or reinforcing element, on the one hand, and by entirely or at least substantially entirely foaming the chambers of the profiled elements with polyurethane of relatively low density, on the other hand, so as to provide for a passive-house-compliant window frame system with high heat insulation properties.

In this connection it is of special advantage to use hollow plastic profile strips foamed with polyurethane foam for glass fixing rails 4, too.

Profiled rails particularly made of fiber-reinforced plastics or fiber-reinforced pressed materials may also be used as profiled stiffening elements 9, 12.

Another embodiment of the invention is shown in Fig. 4, in particular for a window system comprising a casement I of a window wing in combination with a window frame 5, wherein a profiled steel element 9 is incorporated into the largest chamber 7a of the casement frame I as truncated conical or trapizoidally-shaped open hollow profile as a stiffening element and the chamber 7a is completely formed with polyurethane foam.

Occasionally the steel profile element 9 supports or abuts against inwardly oriented projections of the chamber 7a or may abut also against the walls of the chamber itself. In this case, preferably outer chamber 7b, 7c, 7d at the outside of the casement 1, in particular the outside pre-chamber 7b, is not filled with PU foam and, accordingly, this also applies to the outwardly disposed chambers lib, I ic, lid, in particular, to a frame pre-chamber 11 b, of the window frame 5. Within the largest chamber 13 of the window frame there is also a profiled steel element 12 as a stiffening element. Also for this embodiment the explanations above to the embodiment according to Figs. 1 -3 do apply insofar as no deviating particularities are discussed here.

Such profile elements, preferably, are used for windows or other profile systems which are provided with a heat absorbing or heat absorbing coating, i.e. a lesser reflecting coloring (darker coloring) is provided and for which a smooth discharge of radiating heat from the profile element (casement I, window frame 5) as well as from the outer surface of the profiles is preferred, in order to avoid an accumulation of heat within the profile element close to its outer surface.

The foam -free chambers of the casement I or of the window frame 5 -at least partially serve also for a de-watering of the profiles.

Profile elements, such as casement I and window frame 5, having a very bright or white coating or coloring, i.e. a relatively strongly heat reflecting surface or coating, such a heat blockage or accumulation is not to be feared and the outer chambers, in particular the outer pre-chamber 7b, ii b, are filled with foam. Fig. 5 shows such an embodiment with a casement I and a window frame 5, wherein the outside pre-chambers 7b, 11 b in both, the casement 1 as well as within the window frame 5, are completely filled with polyurethane foam (PU foam) and, for example, only the intermediate transitional chambers 7c, 7d or lic, lid, respectively, remain free from the "in situ" filling with foam.

The window frame 5 also here in its largest chamber 13 comprises a stabilizing open steel profile 12 as a stiffening element.

By means of adjusting the degree of foaming of the profile elements in a position of the foamed and foam-free chambers within the profile elements (casement I, window frame 5) the heat transfer profile can be adjusted under consideration of the heat entry which is influenced by the outer coating or coloring (degree of reflection or absorption) of the profile element system.

The invention may, of course, also be utilized for door elements or other profiled elements to be inserted or being inserted into the outer walls of buildings, e.g. in the

field of prefabricated houses.

Claims

SPatent Claims 1. A profiled plastic element, particularly for casements or other glazing carriers or window frames, comprising a plurality of chambers, characterized in that the chambers (7, 11) are entirely foamed with a foaming material (6) and in that in at least one of the chambers (7a, 13) a stiffening element (9, 12)15 provided.
2. The profiled element according to claim 1, characterized in that the foaming material is polyurethane foam (8).
3. The profiled element according to claim I or 2, characterized in that the stiffening element in said chamber (7a, 13) is embedded in said foaming material, particularly in said polyurethane foam (8).
4. The profiled element according to at least one of the preceding claims 1 to 3, characterized in that the stiffening element (9, 12) is a profile, particularly a substantially C-shaped profile or box profile made of steel, of GFK (glass fiber reinforced plastic) or the like.
5. The profiled element according to at least one of the preceding claims I to 4, characterized in that a chamber volume of the chambers (7a, 13) in which the stiffening element (9, 12) is provided is larger than the chamber volume of other chambers (7, 11).
6. The profiled element according to at least one of the preceding claims I to 5, characterized by combining with at least one, preferably a plurality of, glass panes (2), the chamber (7a, 13) being arranged with the stiffening element (9, 12) substantially in a vertical extension of said glass panes (2).
7. The profiled element according to at least one of the preceding claims I to 6, characterized in that at least one outwardly disposed pre-chamber (7b, llb) is provided which is not filled or partially filled with foam.
8. A profiled element substantially as herein described with reference to the accompanying drawings.
9. A casement comprising a profiled element according to at least one of the preceding claims 1 to 8.
10. The casement according to claim 9 comprising a glass fixing rail (4) made of a plastic material and foamed with a foaming material, particularly polyurethane foam.
11. A window frame comprising a profiled element according to at least one of the preceding claims 1 to 8.
12. A combination of casement according to claim 9 or 10 and a window frame according to claim 11.