WO2012004278A1

WO2012004278A1 - Frame profile comprising foamed insert, use of such frame profile, kit of parts of a frame profile and a foam insert and window or door comprising such frame profile

Info

Publication number: WO2012004278A1
Application number: PCT/EP2011/061348
Authority: WO
Inventors: Peter Spanhove; Laura Jonckheere; Mario Genetello
Original assignee: Recticel Nv
Priority date: 2010-07-05
Filing date: 2011-07-05
Publication date: 2012-01-12
Also published as: EP2591196A1; WO2012004277A1; EP2591196B1; EP2591197A1

Abstract

A frame profile comprising a foamed insert, characterized in that said foam is a polymer foam.

Description

FRAME PROFILE COMPRISING FOAMED INSERT, USE OF SUCH FRAME PROFILE, KIT OF PARTS OF A FRAME PROFILE AND A FOAM INSERT AND

WINDOW OR DOOR COMPRISING SUCH FRAME PROFILE Field of the Invention

The present invention concerns a frame profile comprising a foamed insert, in particular a profile for manufacturing a frame of a door or window. Background of the Invention

Window frames and door frames are known to be manufactured in aluminum or PVC or wood. Aluminum frames generally comprise profiles with an inner and an outer shell coupled by a thermal bridge. This thermal bridge is known to comprise a structure in a non-thermal conductive material such as polyamide, extending between the inner shell and outer shell, thereby defining one or several inner chambers. This thermal bridge does not or only on a very limited scale provide structural strength to the profile and should be kept as small as possible to ensure structural integrity of the profile as such. As with PVC frames, the structural strength of the profile is key to minimizing width of the frame for supporting a glass panel or such.

EP 2,080,864 discloses an insert for frame profiles comprising a thermal insulating foam and a structural strengthening band embedded therein. An inconvenience of this type of insert is that it is rather difficult to insert it into the inner chamber of a profile and in that it does not provide a support over the entire surface of the inner chamber wherein the insert is provided.

It is clear from the above that there remains a demand for alternative cost and performance effective frame profiles having equal to improved overall structural properties and which at the same time have improved functionalities. The present invention meets this demand by providing a specific foamed insert for frame profiles.

Summary of the Invention

The present invention concerns a frame profile comprising a foamed insert, characterized in that said foam has a recovery time of minimum 5 seconds at 10% compression, more preferably minimum 7 seconds, most preferably at least 10 seconds.

The foam preferably has a compression modulus of at least 500 kPa.

The foam preferably has a compression strength of at least 70 kPa at 15% compression.

The present invention further addresses the use of a polymer foam as an insert for a profile for the manufacturing of a frame and a door or window comprising such a frame profile. Finally, the present invention concerns a method for manufacturing such a frame profile.

Description of the Invention The frame profile preferably comprises walls defining an inner chamber wherein said foam is inserted in its compressed state and wherein substantially the entire outer surface of the foam insert contacts the inner surface of said inner chamber upon foam expansion.

The foam used for the insert is preferably a polyurethane foam. The foam used for the insert preferably has a compression modulus of at least 500kPa, preferably at least 1000 kPa, more preferably at least 2000 kPa, most preferably at least 2500 kPa. The foam used for the insert preferably has a compression strength at 15% compression of at least 70 kPa, preferably at least 100 kPa, more preferably at least 120 kPa, even more preferably at least 150 kPa, most preferably at least 180 kPa.

The kit of parts, wherein the foam strip is compressed to have a cross section dimension smaller than the cross section dimension of the inner chamber of the profile.

Brief Description of the Drawings Figure 1 represents a cross sectional view of an aluminum type of frame profile according to the present invention;

Figure 2 represents a cross sectional view of a frame profile after insertion of a compressed polymer foam strip;

Figure 3 represents a cross sectional view of a PVC type of frame profile according to the present invention.

Description of a preferred Embodiment

Figure 1 and Figure 2 represent a cross sectional perspective view of an aluminum type of frame profile 1 according to the present invention. The profile comprises an inner shell 2 and an outer shell 3 that are connected to each other by a thermal bridge 4. In the present embodiment, the thermal bridge comprises two legs 5, 6 each extending longitudinally and at a distance from each other between the inner shell 2 and the outer shell 3, thereby defining an inner chamber 7. Figure 3 represents a PVC type frame profile according to the present invention, the profile comprising at least four longitudinally extending legs defining an inner chamber 8. The inner chamber is provided with a foam insert 9 so that substantially the entire outer surface 9 of the foam insert contacts the inner surface of said inner chamber 7, 8.

According to the invention, the foam has a recovery time of minimum 5 seconds at 10% compression, more preferably minimum 7 seconds, most preferably at least 10 seconds.

The recovery time at 10% recovery is defined as the time necessary for unassisted recovery of the foam to its original shape after compressing it by 10% of its height. The test conditions for measuring recovery time are:

- compressing a block of foam with a dimension of 10 cm (length) * 10 cm (width) * 2 cm (height) (after 24 hours of conditioning at 23±2 °C and a relative humidity of 50 ±10 %) in the height direction at a rate of 120mm/min;

Releasing the block and measuring the time for recovery of the block to 100% of its height..

Further according to the invention it is highly preferred that the foam recovers to 100% of its height after 10% compression under the above mentioned test conditions.

The foam preferably has a compression modulus of at least 500 kPa, preferably at least 1000 kPa, preferably at least 2000 kPa, more preferably at least 2500 kPa, most preferably at least 3000 kPa, while compression moduli up to 10000 kPa or more should not be excluded. The foam used for the insert preferably has a compression strength at 15% compression of at least 70 kPa, preferably at least 100 kPa, more preferably at least 120 kPa, even more preferably at least 150 kPa, most preferably at least 180 kPa. The bending strength of the foam preferably ranges between 25 and 500 kPa, when measured with following test method. A polymer foam sample with a dimension of 12 cm (length) * 2 cm (width) * 1 cm (height) is (after 24 hours of conditioning at 23±2 °C and a relative humidity of 50±10 %) positioned on supports that are spaced apart at a distance of 10 cm. The foam sample is bent at a constant rate of 50 mm/min. The bending force is measured at sample fracture or at a maximum bending of 40 mm.

The bending modulus of the foam is preferably at least 500 kPa, preferably at least 750 kPa, more preferably at least 1000 kPa and can range upto 5000 kPa and even 9000 kPa or more.

According to the present invention, the foam is a visco-elastic foam, preferably a polyurethane (PU) or poly-isocyanate based viscoelastic foam. Suitable foams are described US 201 1034575.

The properties, such as recovery time and compression strength of the polyurethane foam are achieved by careful selection of the polyurethane foam forming components, such as the used polyisocyanate (not limited to TDI, MDI, NCO- terminated prepolymer), the used polyol (not limited to a polyether, polyester, polycarbonate, OH-terminated prepolymer), and the used chain extender.

The polymer foam preferably has an open cell structure. The open cell structure can be achieved in various ways, for example by appropriate selection of cell openers and/or surfactants, or by reticulation methods, which are well known to the skilled person. The open cell structure of the foam allows it to be compressed to a much larger degree. Foams with almost closed cells or cells with little openings will tend to have smaller recovery rates as air will only re-enter slowly after compression, resulting in a slowed-down recovery.

The cells in the polymer foam should have a cell diameter in the range of between 100 m and 800 μιτι or lower in order to obtain good thermal insulation properties. The foam is further preferably a hydrophobic foam to prevent water absorption and loss of thermal insulation properties over an extended period of time.

The polymer foam may have a cellular or a micro-cellular structure, having a density (in expanded state) in the range of from 20 kg/m³ and 800 kg/m³. Most preferably the polymer foam has a density between 25 kg/m³ and 200 kg/m³, in view of the ease of compression.

The polymer foam is further characterized by a compression strength (hardness) of between 150 kPa and 300 kPa at 15 % compression and of between 170 and 370 kPa at 40 % compression, when measured with following test method.

A polymer foam sample with a dimension of 10 cm (length) * 10 cm (width) * 2 cm (height) is compressed (after 24 hours of conditioning at 23±2 °C and a relative humidity of 50±10 %) in the height direction at a rate of 120 mm/min. The compression force at 15 % and at 40 % compression is then measured.

The bending strength of the shape memory foam preferably ranges between 25 and 500 kPa, when measured with following test method. A polymer foam sample with a dimension of 12 cm (length) * 2 cm (width) * 1 cm (height) is (after 24 hours of conditioning at 23±2 °C and a relative humidity of 50±10 %) positioned on supports that are spaced apart at a distance of 10 cm. The foam sample is bent at a constant rate of 50 mm/min. The bending force is measured at sample fracture or at a maximum bending of 40 mm. It is believed that a frame profile according to the present invention can exhibit improved structural properties of the thermal bridge or parts of the profile due to the presence of the expanded polymer foam exerting an evenly divided pressure outwardly directed on the side walls of the inner chamber 7, 8. The evenly divided pressure is preferably achieved by dimensioning the foam strip such that when allowed to fully expand to its original dimensions, it has a height or width or a height and width larger than the height and/or width of the inner chamber wherein it is inserted

In the case of the embodiment represented in figure 1 , the profile is assembled by inserting the foam, which will be typically in the form of a strip 10 of compressed polymer foam having cross sectional dimensions (height or width or both) smaller than the cross sectional dimensions (height or width or both) of the inner chamber, in that inner chamber 7, 8, such as represented in figure 2. Compression of the foam strip can be for example achieved on site by introducing an expanded foam strip between a pair of rolls and immediate insertion of the compressed strip in the profile. Clearly it is also possible to compress the strip upfront, example given, by the foam strip manufacturer and transporting the compressed foam strip 10 to the site where the strip is inserted in the profile.

Subsequently, the foam strip will expand until it takes the shape of the inner chamber thereby contacting substantially the entire inner surface of said inner chamber 7, 8. This method, wherein the foam is expanded in the profile before sizing the profile, allows to obtain a good control on the use of the foam and especially to guarantee that the foam is applied over the entire length of the profile without interruption and to prevent that debris originating from further handling of the profile enters the inner chamber. In this way an optimal insulation of the frame by the foam is assured.

The process of:

(a) compressing said foam 9 to a cross section dimension (height or width or both) smaller than the cross section dimensions (height or width or both) of the chamber 7, 8 of the profile 1 ;

(b) transferring said compressed foam obtained by step (a) into the chamber

7, 8) of said profile;

(c) expanding the foam 9 within the chamber 7, 8 of said profile; is preferably performed at a same temperature or substantially constant temperature . Most preferably no heating and or cooling steps are applied for compressing and/or expanding the foam. In case the thermal bridge itself defines an inner chamber, the foam strip can be inserted and expanded before the thermal bridge is connected to the inner and outer shells 2, 3 of the profile. Otherwise, it is also possible to insert the strip in the inner chamber of the profile or the thermal bridge, to size the profile and assemble the frame of a door or window, and to heat the sized profile or frame above Tg of the foam to expand said foam. In this case, heating of the frame can be combined with the production step of drying a lacquer or powder coating provided in the frame. In case handling of the profile is envisaged after insertion of the compressed strip 10 and before expansion thereof, it is preferred to provide an adhesive layer or adhesive strips between the compressed foam and one side wall of the inner chamber in order to allow fixation of the strip and thus to avoid accidental displacement of the foam strip before foam expansion.

Once expanded, the foam strip will remain in place due to friction with the walls of the inner chamber and one can guarantee that substantially the entire inner chamber is filled with foam, thereby assuring thermal insulation, damping and sound insulation properties.

It is noted that when the foam strip is inserted in the profile, the open ends of the profile are preferably sealed with a polyurethane foam or any other sealing material that allows protection of the foam strip during further processing of the profiles such as painting, lacquering, drying or such. The sealants can be removed after processing and before assembling the profiles to a frame.

In another embodiment of the present invention the present invention allows for providing alternative profile structures having different choice of selection of materials, wall thickness of the profiles and/or design of single or multiple chamber profile cross sections. Hence, efficient and cost effective optimization of profiles is obtained.

It is clear that the above described profile can be applied in a broad range of structures such as support structures of for example wall panels and containers or as support structures in automotive and aeronautic applications.

The present invention is by no means limited to the embodiments described above and represented in the accompanying figures. On the contrary, such a plug for sealing an opening in a specific structure can be made in various embodiments while remaining within the scope of the invention.

Claims

1 . A frame profile (1 ) comprising a foamed insert (9), characterized in that said foam is has a recovery time of minimum 5 seconds at 10% compression.

2. The frame profile according to claim 1 , wherein the foam has a compression modulus of at least 500 kPa.

3. The frame profile according to claim 1 , wherein the foam has a compression strength of at least 70 kPa at 15% compression.

4. The frame profile according to claim 1 , wherein the frame profile comprises walls defining an inner chamber (7, 8) wherein said foam is inserted and wherein substantially the entire outer surface of the foam insert (9) contacts the inner surface of said inner chamber (7, 8).

5. The frame profile according to claim 1 , wherein the foam is polyurethane foam.

6. The frame profile according to claim 1 , wherein the foam has a compression modulus of at least 500kPa, preferably at least 1000 kPa, more preferably at least 2000 kPa, most preferably at least 2500 kPa.

7. The frame profile according to claim 1 , wherein the foam is an open cell foam. 8. The frame profile according to claim 1 , wherein the cell diameter is in the range of about Ι ΟΟμιτι to 800μηη or lower.

9. The frame profile according to claim 1 , wherein the foam is a hydrophobic foam. 10. The frame profile according to claim 1 , wherein the polymer foam has a density ranging between 20 kg/m³ and 800 kg/m³, preferably between 25 kg/m³ and 200 kg/m³, when in an expanded state.

1 1 . A kit of parts comprising a frame profile having an inner chamber (7, 8) and a polymer foam strip (10), the foam strip having a recovery time of minimum 5 seconds at 10% compression.

12. The kit of parts according to claim 1 1 , wherein the foam strip (10) is compressed to a cross section dimension (height or width or both) which is smaller than the cross section dimensions (height or width of both) of the inner chamber (7, 8) of the profile (1 ).

13. Door, window or support structure comprising a profile as identified in any of claims 1 to 10.

14. Use of a polymer foam (9) as identified in claims 1 to 10 as an insert for a profile (1 ) for the manufacturing of a frame, preferably a door or window frame.

15. Method for the manufacturing of a polymer foam containing profile comprising the steps of:

(a) compressing said foam (9) to a cross section dimension (height or width or both) smaller than the cross section dimensions (height or width or both) of the chamber (7, 8) of the profile (1 );

(b) transferring said compressed foam obtained by step (a) into the chamber (7, 8) of said profile;

(c) expanding the foam (9) within the chamber (7, 8) of said profile.

16. Method according to claim 15, wherein steps (a) to (c) are performed at the same or substantially the same temperature of the polymer foam.

17. The method according to claim 15, wherein transferring the compressed foam (10) includes conducting and/or inserting the compressed foam in the profile (1 ).

8. The method according to claim 15, wherein conducting and inserting the compressed foam in the profile is done directly upon compressing.