The invention relates to a frame assembly according to the preamble of claim 1 and to a plastic profile frame therefor. The invention further relates to a frame section for said profile frame.
A frame assembly of the above type is known from DE 82 02 221 U1. Another frame assembly comprising fiber-reinforced profile sections is known from DE 203 02 286 U1. A frame assembly comprising reinforcing components containing continuous fiber strips or fiber strands or designed as inserts in the form of rovings, mats or nettings is known from EP 1 245 775 A2. Reinforcement inserts constructed from fibers are also known from EP 0 902 148 A2 and WO 01/06079 A1.
The known fiber-reinforced frame assemblies are either not suited for mass production or else they require quite a high amount of fiber-reinforced plastic material.
Therefore, the object of the present invention is to improve upon a frame assembly of the type mentioned above in such a way that it can be manufactured using mass production techniques and using the least amount of fiber-reinforced plastic materials possible.
This object is accomplished according to the invention by a frame assembly with the features indicated in claim 1.
According to the invention, what was recognized is that the internal hollow spaces of the frame profiles can be delimited by fiber-reinforced reinforcing components only partially without causing loss of stiffness that can have an effect in practice compared to profile layouts in which the hollow spaces are completely delimited by fiber-reinforced materials. This results in a significant reduction in fiber-reinforced material compared to the prior art.
The approach according to the invention of delimiting only a portion of the hollow spaces with fiber-reinforced material also favors the layout of extrusion tools for purposes of coextrusion of such frame profiles since it is not necessary to extrude closed profiles made of un-reinforced material on one hand and those made of reinforced material on the other hand. By designing the reinforcing components so that they are exposed where they border the inner hollow spaces, material savings can be accomplished in the construction of frame profiles of frame components. In general, the reinforcing components must be covered on the visible sides of the frame profiles with un-reinforced plastic material of a certain layer thickness in order to ensure a pleasing surface structure of the visible walls of the frame profiles. In the design according to the invention, the wall thickness of a chamber wall of a frame profile is defined by the required thickness of the reinforcing component on the one hand and by the required thickness of a coating of un-reinforced plastic material on the visible side on the other hand. On the side of the reinforcing components facing the inner hollow spaces, further un-reinforced plastic material is unnecessary and is not added. Coextrusion manufacturing makes it possible to subdivide the cross section of the reinforced frame profiles practically arbitrarily, with fiber-reinforced wall sections on one side and un-reinforced wall sections on the other side. In the process, both the reinforcing components and the un-reinforced plastic components exist as a flowable extrudate. Thus, no pre-manufactured inserts are used, which for the most part are limited with regard to strip width of existing cross sectional shapes to flat or strip-like inserts. Also, complicated manufacturing of a continuous fiber-reinforcement such as is described in EP 1 245 775 A2, which in addition requires complete encasement of the reinforcing component with un-reinforced plastic material, can be eliminated.
An outer wall reinforcement according to claim 2 improves the strength of the frame assembly relative to wind loading.
In inner wall reinforcement according to claim 3 stiffens the frame assembly against forces acting against it from inside. What is preferred is for a profile frame to comprise both an outer wall reinforcement and an inner wall reinforcement since symmetry of thermal expansion behavior of the frame profile can be achieved, in particular. In the embodiments according to claims 2 and 3, a desirable larger distance between reinforcing components and the center of gravity of the profile is provided.
A reinforced folded fitting wall according to claim 4 stiffens the profile frame where it is required to absorb additional forces due to the installation of fittings.
A U-shaped cross section according to claim 5 provides the frame profile with particular stability. The U-shaped base contour can incorporate the entire frame profile, for example by extending over the inner wall, the outer wall and the folded fitting wall. Alternatively, the U-shaped base contour can be incorporated in only one part of a profile wall.
A reinforced inner wall according to claim 6, in other words, a wall that does not border the profile frame on the edge, provides the frame profile with stability where it is particularly required, for example due to static calculations.
A reinforced attachment wall according to claim 7 allows for good absorption of fastening forces by the frame assembly.
A reinforced seal seat according to claim 8 prevents undesired deformation of a seal seat.
A bent or angled shape of at least one reinforcing component according to claim 9 increases the stabilizing effect of the reinforcing component. Provided that absolute stability requirements are met, the reinforcing components can be manufactured with a reduction in the proportion of the cross section that comprises fiber-reinforced plastic extrudate.
Fiber lengths according to claim 10 have proven to be especially suitable for providing a coextrudable fiber-reinforced plastic component that forms a stabile reinforcing component after it cures.
The advantages of plastic profile frames according to claims 11 to 13 and of the frame profile according to claim 14 are the same as the advantages explained above with regard to frame assemblies according to claims 1 to 10.
Exemplary embodiments of the invention are explained below in more detail with the aid of the drawing. Shown are:
In the cross sectional representations of
The sash frame profile 1 is designed as a hollow chamber profile comprising a plurality of hollow chambers. The hollow chamber design is identical in each of the profiles according to
Where the outer reinforcing component 7 delimits the hollow spaces 9 through 11, it is uncovered as seen from the perspective of the hollow spaces 9 to 11. Thus it is not coated with un-reinforced plastic material, but rather is exposed. As such, not only does the outer reinforcing component 7 sit exposed, but all other reinforcing components described below in the exemplary embodiments lie exposed as well if they border hollow spaces.
Embedded into the inner wall 5 is an inner reinforcing component 14 of the sash frame profile 1, said component being bent in areas. The inner reinforcing component 14 acts in a bracing fashion, particularly against wind pressure, i.e. in a force direction from left to right in
A Folded fitting reinforcing component 19 is embedded into the folded fitting wall 6. This follows the entire contour of the folded fitting wall 6. The folded fitting reinforcing component 19 is covered by a folded fitting cover layer 20 that faces the folded fitting, i.e. the window/door frame profile 2, said cover made of non fiber-reinforced plastic.
The folded fitting reinforcing component 19 represents a boundary wall for inside hollow spaces 11, 17 and 18 and for hollow spaces 21, 22 and 23 of the sash frame profile 1. Hollow space 22 represents a central hollow space of the sash frame profile 1. In addition, hollow spaces 21 through 23 are also delimited by the un-reinforced boundary walls 12.
The three reinforcing components 7, 14 and 19 are combined to form an overall reinforcing component 24 of the sash frame profile 1, with an essentially U-shaped base contour as shown in the cross section in
In the cross section shown, the folded fitting reinforcing component 19 and the overall reinforcing component 24 are angled in areas and also bent in areas. This three-dimensional, non-planar configuration of the folded fitting reinforcing component and of the overall reinforcing component increases the stability thereof.
Embedded in an outer wall 25 of the window/door frame profile 2 is an outer reinforcing component 26 of the window/door frame profile 2. The outer reinforcing component 26 follows the entire contour of the outer wall 25. The outer reinforcing component 26 is covered toward the outside of the sash frame profiles 1 by an outer cover layer 27 made of non-reinforced plastic.
The outer reinforcing component 26 forms a boundary wall for outer hollow spaces 28, 29, 30 of the window/door frame profiles 2. Where the outer reinforcing component 26 delimits hollow space 28 on the inside is where the outer reinforcing component is angled. This increases the stability of the outer reinforcing component. Hollow spaces 28 through 30 are also delimited by un-reinforced boundary walls 31. A folded fitting wall 32 and an attachment wall 33, which faces a supporting brick structure (not shown) of the window/door frame profile 2, also represent such un-reinforced boundary walls.
Embedded in an inner wall 34 of the window/door frame profile 2 is an inner reinforcing component 35. The inner reinforcing component 35 is covered by the inside of an inner cover layer 36 made of non-reinforced plastic. The inner reinforcing component 35 represents a boundary wall for inner hollow spaces 37, 38 of the window/door frame profile 2. In addition, hollow spaces 37, 38 are also delimited by the un-reinforced boundary walls 31, 32 and 33.
All reinforcing components 7, 14, 19, 26 and 35 of the frame assembly according to
Sash frame profile 1 according to
The inner reinforcing component 39 runs spaced apart from the un-reinforced outer wall 4 in the embodiment according to
The inner reinforcing component 40 runs at a distance to the inner reinforcing component parallel to the outer wall 4 between the rabbet base wall 13 and the folded fitting wall 6. The inner reinforcing component 40 represents a boundary wall for hollow spaces 21 and 22. Hollow space 22 is also delimited by the un-reinforced rabbet base wall 13, the un-reinforced folded fitting wall 6 and the inner reinforcing component 41. The inner reinforcing component comprises two ribs at a distance, and is angled in sections proximate to said ribs, which increases the stability of the inner reinforcing component 40. Inner reinforcing component 41 also comprises such ribs, which increase the stability of the component.
Inner reinforcing component 41 runs parallel to inner reinforcing component 40, likewise between the rabbet base wall 13 and the folded fitting wall 6, and also delimits hollow space 23. This is likewise delimited by the un-reinforced rabbet base wall 13, the un-reinforced boundary wall 12 and by the un-reinforced folded fitting wall 6 and finally by inner reinforcing component 42.
The latter runs parallel to and at a distance from the un-reinforced inner wall 5 in the case of the embodiment according to
The window/door frame profile 2 according to
Inner reinforcing component 43 runs at an angle to un-reinforced outer wall 25 at a distance thereto in the case of the embodiment according to
The latter reinforcing component runs at a distance to reinforcing component 43 likewise between folded fitting wall 32 and attachment wall 33. Inner reinforcing component 44 also delimits a central hollow space 48 of the window/door frame profile 2 in addition to delimited hollow space 47. The central hollow space is also delimited by un-reinforced folded fitting wall 32, un-reinforced attachment wall 33 and by inner reinforcing component 45.
The latter reinforcing component runs between folded fitting wall 32 and attachment wall 33 at a distance to un-reinforced inner wall 34 in the case of the embodiment according to
This component runs between inner reinforcing component 45 and inner wall 34 and parallel to these two walls. Inner reinforcing component 46 delimits hollow spaces 37, 38, 49 and 50. Hollow spaces 37 and 38 are also delimited by un-reinforced boundary wall 31, un-reinforced folded fitting wall 32, un-reinforced attachment wall 33 and by un-reinforced inner wall 34.
Reinforcing components 43 through 46 on one side and 47 through 50 on the other side run substantially parallel to one another and are not connected together. Inner reinforcing components 39 and 46 intersect with un-reinforced boundary walls 12 and 31. Inner reinforcing components 43 and 45 form a T-configuration with inner un-reinforced boundary walls 31. Inner reinforcing components 40, 41, 42, and 44 represent reinforcing walls that run freely between boundary walls of the frame profiles 1, 2.
In the embodiment according to
Also, the sash frame profile 1 according to
In addition to inner reinforcing components 43 through 46, the window/door frame profile 2 according to
Inner reinforcing component 55 forms an overall reinforcing component 43, 55 together with inner reinforcing component 43, said overall reinforcing component having a three-dimensional overall structure, i.e. is non-planar and thus is designed so as to be angled in areas. Inner reinforcing component 56 runs between un-reinforced inner wall 34 and inner reinforcing component 45 and intersects inner reinforcing component 46. Inner reinforcing components 45, 46, 56 form an overall reinforcing component that has a three-dimensional structure for increased stability, and that is angled in areas. Inner reinforcing component 56 delimits hollow spaces 37, 38, 49 and 50.
In the embodiment of the sash frame profile 1 according to
Sash frame profile 1 according to
In the embodiment according to
Window/door frame profile 2 according to
Sash frame profile 1 according to
Sash frame profile 1 further comprises a folded fitting sectional reinforcing component 67 that is embedded in a groove section 68 of folded fitting wall 6. Folded fitting sectional reinforcing component 67 is curved in the shape of a U in cross section and comprises two stabilizing ribs. A groove section cover layer 69 covers the folded fitting sectional reinforcing component 67 toward the folded fitting. Folded fitting sectional reinforcing component 67 delimits central hollow space 22 of the sash frame profile 1. Folded fitting sectional reinforcing component 67 has a substantially U-shaped base contour.
Sash frame profile 1 according to
Window/door frame profile 2 also comprises a seal seat reinforcing component 63 having a design corresponding to the seal seat reinforcing component 63 already described above in connection with sash frame profile 1. This seal seat reinforcing component 63 of window/door frame profile 2 delimits hollow space 28. window/door frame profile 2 according to
Window/door frame profile 2 according to
Frame profiles 1, 2 of the embodiments described above represent co-extrudates comprising the respective reinforcing components and un-reinforced boundary walls. Prior to extrusion, fibers are added to the plastic material that is plasticized in the extruder during extrusion of the reinforcing components; these fibers therefore form a plastic mass that can flow together with the plastic matrix during extrusion of the reinforcing components.
The frame profiles 1, 2 are made of glass-fiber reinforced and otherwise un-reinforced high-impact strength PVC in the area of the reinforcing components.
This PVC has a K value describing its flow characteristics, i.e. its melt viscosity in particular, of between 50 and 60. This K value can be converted to intrinsic viscosity of the PVC using the following relationship:
[η]=2.303×(75 k2+k) with K value=1000 k
The profile elements have a glass fiber fraction of at most 25 wt.-%, preferably at most 20 wt.-%, more preferably at most 15 wt.-%, with a length of the individual glass fibers of between 1 and 3 mm.
The cover layers can be made of a different non-fibrous, high impact strength plastic material, including for example PBT (polybutylene terephthalate). Alternatively, the cover layers can also be made of ASA (acrylonitrile-styrene-acrylic ester) or SB (styrene-butadiene).
Alternative materials for the fiber-reinforced profile frames include ABS (acrylonitrile/butadiene/styrene), ASA (acrylonitrile/styrene/acrylic ester) and SB (styrene/butadiene). These copolymers are well suited for fiber-reinforcement and for tailoring the coefficients of thermal expansion of the profile frame to match the coefficients of thermal expansion of the glass panes of an insulating glazing.
The fiber reinforcement of the fiber-reinforced components of the profile frame, i.e. the reinforcing components thereof, can also be done using organic polymer-based fibers, in particular PAN (polyacrylonitrile), as an alternative to glass fibers. It is also possible to use a higher fiber fraction than 15 or 20 wt.-% with such fibers. Despite this higher fiber fraction, the material remains easily welded. In the embodiments of the reinforcing components illustrated, the fibers have a maximum length of 10 mm. Embodiments are also possible with a maximum fiber length of 5 mm.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP08/06452 | 8/6/2008 | WO | 00 | 2/15/2010 |