Patent Application
20210372194
This patent application claims priority to German Patent Application No. 102020114544.6, filed May 29, 2020, which is incorporated herein by reference in its entirety.
The present disclosure relates to an extrusion profile, in particular made of a polymer material, such as Polyvinyl chloride (PVC), for a door system and/or a window system, for example of a passive house. Furthermore, the present disclosure also relates to a method for manufacturing an extrusion profile. Furthermore, the present disclosure provides a door system and/or a window system comprising an extrusion profile.
Typically, PVC extrusion profiles for windows and/or doors have both a steel stiffener structural reasons and to enable the screw connection of fittings, and an insulation filling of either PolyStyrene (PS) or Expanded PolyStyrene (EPS) to achieve a good heat transfer coefficient (U-value). For example, roll-formed steel profiles are used, which on the one hand provide the static features for the windows and at the same time serve as screw basis for the fittings. In order to achieve a significantly improved U-value, it is necessary to insert insulation foam material made of PS or EPS into the hollow chambers of the extrusion profile. For example, the insulation material is inserted into the steel stiffener in the hollow chambers of the extrusion profiles or they are completely filled with foam, so that the foam material engages into a firm connection with the extrusion profile. The use of steel profiles is also necessary in so far as they serve as a counter bearing for the screw connection in the masonry and the fittings.
DE 10 2008 00 495 A1 discloses such a known Polyurethane (PU) a window frame profile with the hollow chamber and a foam insulation material completely filling the same. Additional reinforcement elements in the form of stability-increasing fiber elements, cubes made of plastics or a fiber composite material or a fitting part are incorporated in the insulation material to ensure the required mechanical stability of the window frame profile. The reinforcing elements are already placed in the molding tool during the foaming of the foam insulation material and overmoulded by the foam. Subsequently, the foam insulation material stiffened with the reinforcement element is overmoulded by a rigid polyurethane sheathing in an injection molding process. Disadvantages of the known extrusion profiles are the complex production as well as the high number of components in order to ensure, on one hand, a sufficient strength or rigidity of the extrusion profiles and, on the other hand, a sufficient insulation effect.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the embodiments of the present disclosure and, together with the description, further serve to explain the principles of the embodiments and to enable a person skilled in the pertinent art to make and use the embodiments.
The exemplary embodiments of the present disclosure will be described with reference to the accompanying drawings. Elements, features and components that are identical, functionally identical and have the same effect are—insofar as is not stated otherwise—respectively provided with the same reference character.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. However, it will be apparent to those skilled in the art that the embodiments, including structures, systems, and methods, may be practiced without these specific details. The description and representation herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, have not been described in detail to avoid unnecessarily obscuring embodiments of the disclosure.
An object of the present disclosure is to overcome the disadvantages known in the prior art, including to provide an extrusion profile which is simpler and/or can be produced with fewer components, and which in particular has a right higher rigidity and/or better insulation effect.
Accordingly, an extrusion profile is provided for a door system and/or window system, in particular for a door frame and/or a window frame, for example of a passive house. The extrusion profile may for example be made of a polymer material, such as PVC. The extrusion profile is manufactured by an extrusion process which is cost-effective and energy efficient for large production volumes. The extrusion profile is defined by an extrusion direction which defines the longitudinal direction of the extrusion profile, in which the extrusion profile does not substantially change in cross-section. The extrusion profiles according to the disclosure can be used, for example, for door systems and/or window systems comprising a door profile frame and/or window profile frame, for example a frame profile of the pivoting or linear sliding sash, a frame profile of a stationary so-called fixed sash, a faceplate or a mullion, a profile frame, door frame and/or window frame in a building wall reception, such as a shroud profile, or complementarity frame parts, such as for example a lining profile or a shield profile.
The extrusion profile comprises at least one hollow chamber extending in the extrusion direction and delimited by profile walls. Furthermore, the extrusion profile comprises a plurality of hollow chambers extending in the extrusion direction and delimited by profile walls. Generally, the extrusion profile is largely hollow, but may have, in particular thin-walled, profile walls for delimiting and dividing the interior, which profile walls delimit the hollow chambers and/or connector profile wall forming the outside of the extrusion profile. A hollow chamber does not necessarily need to be completely closed in the circumferential direction but may in some cases be designed to be open by means of slates or larger openings. In an exemplary embodiment, the at least one hollow chamber is closed in the circumferential direction (around the longitudinal direction). For example, the at least one hollow chamber is open in the extrusion direction all longitudinal direction to at least one assigned, in particular to both sides.
According to the disclosure, an insulation core of foam material is arranged in the at least one hollow chamber, which core has a compressive strength of at least 0.3 N/mm2. To determine the compressive strength, the standard test method according to ASTM D 1621 can be used, by means of which the compressive properties of rigid foams, in particular rigid polymer material foams, can be determined and tested. For example, the foam material is PET, in particular the material Kerdyn®, or a foam material having similar characteristic values, such as for example the foam known under the trademark ‘wingo-HT-Isolationsschaumstoff’ (wingo-HT-isolation foam). A significant advantage of using a foam insulation core with a minimum compressive strength of 0.3 N/mm2 is that further stiffening measures, such as the steel stiffeners usually inserted into the hollow chambers, can be dispensed with. This is accompanied by further considerable advantages: reduced weight and thus costs, in particular freight costs, as well as easier assembly. The foam insulation core can be inserted into the hollow chamber in any way, for example by being pushed in. In particular, the use of a foam material according to the disclosure, such as the Polyethylene terephthalate (PET) foam, for example the Kerdyn® material, or the wingo-HT-isolation foam, for the insulation core has been found to be particularly advantageous for use in extrusion profiles according to the genus for door systems and/or window systems, for example in a passive house. PET is a thermoplastic from the polyester family produced by polycondensation. In general, the foam material according to the disclosure is a thermoplastic form material with high mechanical and thermal properties and a high resistance to moisture. As a result, the extrusion profile can meet the structural and rigidity requirements. Furthermore, the foam material according to an exemplary embodiment of the disclosure, in particular the PET-foam, preferably the Kerdyn® foam material, or the wingo-HT-isolation foam, is characterized by the high thermal insulation properties and the good fire behavior, so that especially a passive house can achieve a good insulation value. For example, the foam material may be foamed PET, in particular Kerdyn® foam material, in particular made of a recycled and/or recyclable polymer material, for example made of PET. A further advantage lies in the processing of the foam material according to the disclosure, in particular the PET foam material, such as the Kerdyn® foam material. This can be cut to size in a simple manner and, for example, attached to one another in any longitudinal direction, for example welded to butt, so that essentially no scrap or waste is produced. Surprisingly, it has been shown that when arranging a foam insulation core with the minimum compressive strength of 0.3 N/mm2, an extrusion profile is created which is easy to manufacture and which, on the one hand, has increased rigidity and thus statics, and, on the other hand, provides a good insulation effect. With regard to the foam material according to the disclosure, in particular the PET foam, such as the Kerdyn® foam material, or the wingo-HT-isolation foam, it has surprisingly still been found that the insulation core can be screw-connected to the extrusion profile, in particular to its inner profile walls and/or to a profile wall forming the outer sides of the extrusion profile. This means that the foam material used according to the disclosure, in particular the PET foam material, such as the Kerdyn® material, or the wingo-HT-isolation foam, has sufficient resistance to the screw pulling out and/or tearing out. Additional bonding of the insulation core to the profile walls of the extrusion profile is not necessary. As a result, the foam material can be processed with conventional woodworking machines, so that a particularly simple shaping as possible without requiring special tools and/or machines.
The wingo-HT insulation foam is generally a high-temperature foam that can have a bulk density in the range from 100 kg/m3 to 200 kg/m3, in particular in the range from 120 kg/m3 to 180 kg/m3 or in the range from 140 kg/m3 to 160 kg/m3. A thermal conductivity according to DIN EN ISO 12667/10456 is less than 0.05 W/(mK), in particular at most 0.041 W/(mK) or 0.035 W/(mK), for example 0.031 W/(mK). A water absorption according to ISO 62 can be less than 5%, in particular less than 4%, 3%, 2% or 1%. Another advantage is the high temperature resistance from −40° C. to 220° C.
In an exemplary embodiment of the profile according to the disclosure, a stiffening profile, for example U-shaped or C-shaped stiffening profile, in particular of metal, such as steel, is arranged in the at least one hollow chamber. The stiffening profile may have a constant cross section in the longitudinal direction and/or be thin-walled. This means that a wall thickness of the stiffening profile walls may be significantly smaller in dimension than the outer cross-sectional dimension and/or the longitudinal dimension. For example, the stiffening profile is form fitted with respect to the hollow chamber. For example, the stiffening profile may abut 2, 3 or 4 profile walls delimiting the hollow chamber. The stiffening profile may be hollow and thus delimit or form profile chamber, and the insulation core may be arranged in the profile chamber of the stiffening profile. For example, the insulation core and the stiffening profile are preassembled and placed together in the hollow chamber. Alternatively, it is possible to first insert the stiffening profile into the hollow chamber and subsequently insulation core into the profile chamber of the stiffening profile. In an exemplary embodiment, the insulation core occupies the profile chamber substantially completely, in particular for more than 90%, in particular for more than 95% or for more than 98%. The application of a stiffening profile has in particular shown to be advantageous in applications of the extrusion profile in which particularly high requirements are placed on the statics and/or screw-resistance.
In an exemplary embodiment of the extrusion profile according to the disclosure, the foam material has a minimal compressive strength of 0.5 N/mm2, 0.75 N/mm2, 1.0 N/mm2, 1.25 N/mm2, 1.5 N/mm2, 1.75 N/mm2, 2 N/mm2, 2.25 N/mm2, 2.5 N/mm2, 2.75 N/mm2, or 3 N/mm2. The values of the compressive strength are determined with the measuring method according to ASTM D 1621.
According to a further exemplary embodiment of the extrusion profile according to the disclosure, the foam material has a thermal conductivity of less than 0.05 W/(mK), in particular at most 0.041 W/(mK) or 0.035 W/(mK). The thermal conductivity can be determined using the standard DIN 12667 “thermal technical behavior of building materials and building products—determination of the thermal resistance using the plate device method with the heat flow measuring plate device products with high and medium thermal resistance”, and the thermal transmittance using DIN EN ISO 6946 “building components—thermal resistance and thermal transmittance—calculation method”. The heat transfer coefficient, also called the U-value, is a measure of the heat transfer through a solid body from a fluid. In relation to a window and/or a door, it indicates the heat flow, i.e. a heat energy per unit time, per area from the door and/or window and per Kelvin temperature difference inside a building and outside of the building. Thermal conductivity is generally a material property that determines the heat flow through a material due to thermal conduction. In general, the lower the thermal conductivity, the better it's thermal insulation. By means of the foam material used, as U-value in the range of 0.7 to 1.3 W/(m2K) can be achieved for a window and/or door. Due to the selected materials and properties, the extrusion profile according to the disclosure has particularly good thermal insulation properties, so that it is particularly suitable for passive houses. In principle, it is conceivable to use phones with the thermal conductivity of less than 0.1 W/(mK).
In another exemplary embodiment of the present disclosure, the firm has an axis-parallel screw extraction resistance, measured at a thickness of the insulation core of about 20 mm, of at least 100 N, in particular of at least 150 N, 200 N or of at least 210 N. The screw extraction resistance can be determined on the basis of standard EN 320. The screw extraction resistance is a generally a measure of the force required to extract a defined screw from the test specimen, in this case the foam insulation core. Surprisingly, it has been found that contrary to the prejudice that foam materials cannot be screwed to extrusion profiles, the foam material used according to the disclosure can be sufficiently reliably screwed to the profile walls, in particular of a polymer material. Additional bonding or gluing or the like is not necessary. Thus, in particular, assembly is facilitated as well as recycling is improved.
According to another axillary embodiment of the extrusion profile according to the disclosure, the insulation core is inserted into the hollow chamber in the extrusion direction. The extrusion profile can thus be produced in a simple manner. An extrusion basis profile can be produced by extrusion, and in particular simultaneously or sequentially thereto, a foam material insulation core adapted in this respect can be produced and processed. Subsequently, the foam insulation core can be inserted, in particular pushed, into a whole chamber of the extrusion base profile in the extrusion or longitudinal direction. After the insulation core has been inserted translationally into the hollow chamber, the insulation core can be screwed to the extrusion base profile so that a rigid connection is established.
In another exemplary embodiment of the extrusion profile according to the disclosure, the insulation core is adapted in shape or shape-matched with respect to the hollow chamber. For example, an outer dimension of the insulation core may be matched with respect to an inner dimension of the hollow chamber. For example, an undersize may be present between the insulation core and the hollow chamber. Further, an exterior dimension of the insulation core may be smaller than an inner dimension of the hollow chamber. Alternatively or additionally, a particularly circumferential slot in the range of 0 mm to 1.5 mm viewed with respect to the extrusion direction, may be present between an exterior dimension of the insulation core and an interior dimension of the hollow chamber. Thereby it is possible that the insulation core occupies at least 90% and/or no more than 100% of the world chamber. At an inner side of profile wall delimiting the hollow chamber, facing towards the insulation core, at least one spacing can may be provided. In this case, the insulation core may engage the spacing can so that a gap of free space is present around the spacing cam between the insulation core and the profile wall.
In an exemplary embodiment of the extrusion profile according to the disclosure, the insulation core and the hollow chamber are shape-matched to one another, that an amplitude of movement of the insulation core in the hollow chamber in the crosswise direction with regard to the extrusion direction of maximally 3 mm, in particular maximally 2 mm or of maximally 1.5 mm, are permitted. The maximal amplitude of movement ascertains that the insulation core does not wobble or shake in the hollow chamber. It shall be clear that the edges of the insulation core can be rounded such that a larger distance between insulation core and hollow chamber can be present. Thereby, however, the maximal amplitude of movement between the insulation core and hollow chamber is nevertheless ascertained.
According to a further exemplary embodiment of the present disclosure, in a preassembly state there is an oversize of the insulation core with respect to the hollow chamber of up to 1.5 mm and/or of up to 10% of a hollow chamber cross-section. For example, the insulation core is axially pressed into the hollow chamber and/or fixed within the hollow chamber by means of pressing. In a further exemplary embodiment of the extrusion profile according to the disclosure, the insulation core is screw-connected to at least one profile delimiting the hollow chamber. For example, a countersunk screw may be used. For example, the screw is a countersunk in the profile wall. For example, the insulation core including the profile wall may be screwed to a building support, such as a building masonry.
According to an exemplary further development, the extrusion profile according to the disclosure comprises a plurality of hollow chambers, wherein in insulation core is arranged, in particular inserted, in at least two hollow chambers in each case. For example, if particularly high requirements are placed on statics and/or thermal insulation, at least two insulation cores can be used.
In another exemplary embodiment of the present disclosure, an attachment profile, such as a width expander profile, a shield profile, or a lining ledge profile, is connected to the extrusion profile or in the extrusion basis profile. The attachment profile can be manufactured by extrusion and/or have at least profile chamber extending in longitudinal direction, in particular extrusion direction, and delimited by attachment profile walls, in which an insulation core of the foam material, in particular PET, such as Kerdyn®, or wingo-HT-isolation foam, having a compressive strength of at least 0.3 N/mm2 is arranged. The profile chambers do substantially not change their cross-section and/or their dimensions in the longitudinal, in particular extrusion direction, and are designed opened towards at least one side with respect to the extrusion direction.
According to an exemplary further development, the attachment profile and of the extrusion profile have a fastening structure for positively and/or frictionally attaching to each other. For example, the fastening structure can comprise latching and/or hooking means. For example, the fastening structure is produced in one manufacturing step and/or from one piece with the remaining extrusion profile or attachment profile, in particular produced by an injection molding process, in particular from a polymer material.
In a further exemplary embodiment of the extrusion profile according to the disclosure, the hollow chamber and the insulating core are attached to each other, for example, by a force fit, a form fit and/or a material fit. The fastening can be realized, for example, by screwing, pinning or by other suitable fastening means, such as clips, sleeves or the like. In addition, material-locking fastenings are possible. For example, the insulating core can be bonded or glued to the hollow chamber, for example by means of wet bonding or dry bonding. One advantage of fastening the hollow chamber and the insulating core is that the extrusion profile can be handled more easily. For example, an insulation core up to 7 m long can be inserted into the hollow chamber and then attached. Such an extrusion profile can then be handed over to a window manufacturer or the like, ensuring that the hollow chamber and insulation core are fastened together. Another advantage is that the insulation core and hollow chamber can be cut, for example by sawing, to size at the same time. Cores with individually cut lengths are no longer necessary. This results in a considerable cost-saving potential. Furthermore, the material used for the foam core allows the hollow chamber and the insulating core to be corner-welded at the same time. This means that the corner strength can be increased by welding the insulation core over the entire surface. Furthermore, the insulation values are improved by a circumferential weld.
In an exemplary embodiment, the hollow chamber and the insulating core are attached to one another by a mechanical force input, for example by knurling, in particular from the outside, i.e. from the hollow chamber, and/or by a thermal energy, in such a way that the hollow chamber and the insulating core engage each other, in particular interlock and/or hook, as a result of a deformation of the hollow chamber and the insulating core resulting from the mechanical force input and/or thermal heat input. For example, the hollow chamber can be deformed by a mechanical force input from the outside in such a way that a fastening lug is formed which extends into the material of the insulating core. Furthermore, it is possible to create an attachment via the resulting perforation structure, in particular from the outside, i.e. from the hollow chamber, of the hollow chamber and at least partially of the insulating core, by means of punctual perforation. The perforations can then be welded or closed with another filling material, for example an end cap, or filled with plastic material by means of a hollow needle, for example with or without heating the material of the hollow chamber.
According to a further aspect of the present disclosure, which can be combined with the preceding aspects and exemplary embodiments, a method for manufacturing an extrusion profile, in particular according to the disclosure, is provided. The extrusion profile can be made, for example, of the polymer material, such as PVC, and can be used for a door system and/or a window system, for example of the passive house.
In the manufacturing process according to the disclosure, an extrusion basis profile having at least one hollow chamber extending in the extrusion direction and delimited by profile walls is manufactured by means of extrusion, in particular a polymer material extrusion. In the extrusion direction, the cross-section of the hollow chamber and/or of the extrusion basis profile does not substantially change. Furthermore, the hollow chamber may be designed to be open towards at least one side.
According to the disclosure, an insulating core made of foam, in particular PET, such as Kerdyn®, or the wingo-HT-isolation foam, which has a compressive strength of at least 0.3 N/mm2, is inserted, in particular pushed, into the hollow chamber in the extrusion direction.
According to an exemplary embodiment of the method of the disclosure, the method is adapted to produce an extrusion profile formed according to any of the previously described aspects and/or exemplary embodiments.
According to a further aspect of the present disclosure, which may be combined with the preceding aspects and exemplary embodiments, a door system and/or window system is provided, for example for a passive house. The door system and/or window system comprises at least one extrusion profile sectionally forming a profile frame and/profile attachment part of the door and/or window, which extrusion profile is formed according to one of the previously described aspects and/or exemplary embodiments and/or is produced by manufacturing process according to the disclosure.
In the following description of exemplary embodiments of the present disclosure, an extrusion profile according to the disclosure is generally designated with reference numeral 1. For the further description it may be understood that the extrusion profiles 1 are made of a polymer material, such as PVC, through an extrusion process. The extrusion direction E is thereby oriented in the drawing plane. The extrusion profiles 1 according to the disclosure are used in doors or windows, in particular in door frames or window frames. For example, the extrusion profile 1 may be a frame profile, sash profile, a width expander profile of the sash or of a frame, a mullion profile, a shield profile, a shield sash profile, a shroud profile, in particular in sliding doors or windows, or a lining ledge profile.
In the exemplary embodiments of
The extrusion profile according to the disclosure, as well as the extruder profile 3, has a circumferential wall 5 or 7 forming an outside of the profile, which defines a substantially constant cross-section or outer shape is viewed in the extrusion direction E. Internally, the extrusion profile 1 and the extruded profile 3 may in particular have thin-walled profile webs or profile walls 9 which, together with another profile wall 9 and/or the outer wall 5, 7, define hollow chambers 10, 13, 15, 17, 19, 21, 47, 67, 91, 93, 95, 81. The hollow chamber is generally indicated with reference numeral 10, individual hollow chambers may be indicated with a further reference numeral. The profile walls 9 hollow chambers 10 can be produced in a simple manner by means of the extrusion process.
The extrusion profile 1 according to an exemplary embodiment of the disclosure has an insulation core 20 of the material arranged in 1 of the hollow chambers 10, namely in the hollow chamber 21, which core has a compressive strength of at least 0.3 N/mm2. An insulation core is generally indicated by the reference numeral 20, and individual insulation cores may be indicated by further reference numeral. For example, the insulation core 20 comprises PET, such as Kerdyn®, in particular Kerdyn® 115, or the wingo-HT-isolation foam. The inventors of the present disclosure found that by using a foam insulation core having the predetermined compressive strength of at least 0.3 N/mm 2, the extrusion profiles 1 according to the disclosure, when used in doors or windows, in particular of passive houses, ensure as well as the requirements in terms of statics and in terms of insulation property. A significant advantage is that additional stiffening means, such as metal stiffeners of fasteners, can be dispensed with.
As can be seen in
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The embodiment of the door and/or window system according to
In
In embodiment variant b, the extruded profiles 3 forming the sash is are also designed as extrusion profiles 1 according to the disclosure and have foam insulation cores.
The embodiment of the door and/or window system 100 of
The schematic sectional views of extrusion profiles 1 according to exemplary embodiments of the disclosure in
In
In
The features disclosed in the above description, figures and claims may be of relevance, both individually and in any combination thereof, for the realization of the disclosure in its various embodiments.
To enable those skilled in the art to better understand the solution of the present disclosure, the technical solution in the embodiments of the present disclosure is described clearly and completely below in conjunction with the drawings in the embodiments of the present disclosure. Obviously, the embodiments described are only some, not all, of the embodiments of the present disclosure. All other embodiments obtained by those skilled in the art on the basis of the embodiments in the present disclosure without any creative effort should fall within the scope of protection of the present disclosure.
It should be noted that the terms “first”, “second”, etc. in the description, claims and abovementioned drawings of the present disclosure are used to distinguish between similar objects, but not necessarily used to describe a specific order or sequence. It should be understood that data used in this way can be interchanged as appropriate so that the embodiments of the present disclosure described here can be implemented in an order other than those shown or described here. In addition, the terms “comprise” and “have” and any variants thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or equipment comprising a series of steps or modules or units is not necessarily limited to those steps or modules or units which are clearly listed, but may comprise other steps or modules or units which are not clearly listed or are intrinsic to such processes, methods, products or equipment.
References in the specification to “one embodiment,” “an embodiment,” “an exemplary embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
The exemplary embodiments described herein are provided for illustrative purposes, and are not limiting. Other exemplary embodiments are possible, and modifications may be made to the exemplary embodiments. Therefore, the specification is not meant to limit the disclosure. Rather, the scope of the disclosure is defined only in accordance with the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102020114544.6 | May 2020 | DE | national |
