Patent Application
20100086710
Applicant claims priority under 35 U.S.C. §119 of German Application No. 10 2008 050 541.2 filed on Oct. 6, 2008.
1. Field of the Invention
The present invention relates to a hollow profile made of metal, particularly a hollow profile sash bar made of metal, preferably of aluminum, for insulated glazing, as well as to a method and a device for the production of the hollow profile.
2. The Prior Art
In insulated glazing, bars are disposed between two panes of glass of windows, for example. The bars are flat hollow profile rods that are usually interconnected by cross-connection pieces and are connected with the spacer frame of the insulated glazing using connection plugs. In this connection, the bars are preferably coated with paint, in order to adapt the color of the bars to the color of the window frames.
It is known to produce the sash bars by extrusion, as extruded hollow profiles, and subsequently to apply the desired paint by electrostatic powder coating. A disadvantage of this method is that the wall thickness of the extruded hollow profiles, at 0.6 mm to 0.8 mm, is relatively great because it is not possible to produce thin wall thickness values using the extrusion method. As a consequence, sash bars produced using the extrusion method are relatively heavy and expensive, because a lot of material is required. Furthermore, coating with the desired paint can take place only after profiling of the hollow profile extrudate. Furthermore, powder coating involves the problem that the field lines are concentrated at sharp edges. Frequently, over-coating of the work piece edges is the result. Also, a surface coated by powder coating is relatively uneven and a relatively large amount of paint is required.
Another method for the production of hollow profile sash bars is known from EP 0 577 150 B1. Production according to EP 0 577 150 B1 takes place by means of rolling deformation. In this connection, the desired paint is applied to a metallic flat band material using a roller printing system. Subsequently, the flat band material is cut into strips, and these strips are deformed by means of bending by rollers, until the two longitudinal edges of the strips abut one another. In this connection, a flat endless hollow profile rod is formed. The two abutting edges are subsequently welded to one another. It is advantageous in this method that profiles having a low wall thickness can be produced. Furthermore, clearly less paint is needed for the paint application than in the case of powder coating, and a smoother surface can be produced. The rolling and bending method, however, has the disadvantage that the paint comes off in the region of the weld seam, during welding, and that the weld seam is visible, which is unattractive. In order to overcome this disadvantage, EP 0 577 150 B1 discloses providing a profile retraction in the region of the weld seam after welding. The weld seam is provided in the region of the bottom of the profile retraction so that the weld seam is disposed so as to be optically covered.
Furthermore, it is known to produce hollow profile bars using the rolling and bending method, but without applying paint to the flat band material before rolling and bending. Instead, the finished, bent and profiled hollow profile bar is powder coated. The weld seam can be made invisible by subsequent coating using powder coating, in place of the imprinting application according to EP 0 577 150 B1. Powder coating, however, has the disadvantages mentioned above and is possible only in thick layers in order to achieve full coverage.
Furthermore, it is known, outside of sash bar production in the case of round pipes welded in the longitudinal direction, to scrape these pipes on the outside, in certain regions, in order to obtain a good surface. This scraping is done by means of a ring-shaped knife carrier head, which has three knife plates that are disposed uniformly distributed in the circumference direction of the knife carrier head, whereby the knife carrier head oscillates about its ring axis. The welded round pipe is moved through the knife carrier head, whereby one of the knives, in each instance, stands in engagement with the round pipe in such a manner that the outside of the round pipe is scraped off, in certain regions.
In summary, it should be stated that the method of EP 0 577 150 B1 is the one that has best proven itself, particularly due to the wall thickness of the profiles produced using this method, and the low amount of paint required for the paint application.
It is therefore an object of the present invention to further develop the method of EP 0 577 150 B1 so that a cost-advantageous, simple, and efficient method for the production of hollow profiles made of metal, particularly of hollow profile sash bars for insulated glazing, is made available, with the hollow profile produced having the lowest possible wall thickness and a surface uniformly coated with paint.
Another object of the invention is to make available a device for cost-advantageous, simple, and efficient production of such hollow profiles made of metal for insulated glazing.
Another object of the present invention is to make available such a cost-advantageous and easy to produce hollow profile made of metal, particularly a hollow profile sash bar for sash bars for insulated glazing, which has the lowest possible wall thickness and a surface uniformly coated with paint.
In one aspect, these and other objects are achieved according to the invention by a hollow profile, particularly by a hollow profile sash bar for sash bars made of metal, welded together in the longitudinal direction, in the region of two abutting edges, by means of a longitudinal weld seam having a profile wall and an outer profile surface imprinted with paint, wherein the longitudinal wall seam has an outer weld seam that does not project beyond the profile wall on the outside, and the outer weld seam surface is imprinted with paint.
In another aspect, a device is provided according to the invention for production, particularly continuous production, of a hollow profile made of metal, particularly a hollow profile sash bar for sash bars, having a profile wall and an outer profile surface, particularly for the production of a hollow profile according to the first aspect of the invention above.
The device has a device for bending by rollers for producing a longitudinally slit endless hollow profile having two abutting edges that lie against one another, made from a metal strip coated with paint on at least one side, a welding device for producing a longitudinal weld seam by means of welding the two abutting edges to one another, and a profiling device for introducing profilings into the welded endless hollow profile to produce the hollow profile.
The device further includes a weld seam ablation device, particularly one disposed after the welding device and ahead of the profiling device, for externally ablating, particularly scraping off the longitudinal weld seam, to produce a smooth outer weld seam surface, and a paint application device, particularly following the profiling device, for imprinting the outer weld seam surface and preferably the adjacent region of the outer profile surface with paint, particularly in strip shape.
In a third aspect, a method is provided according to the invention for production, particularly continuous production, of a hollow profile made of metal, particularly a hollow-profile sash bar for sash bars, having a profile wall and an outer profile surface, particularly for the production of a hollow profile according to the first aspect of the invention above.
In accordance with the method, production takes place of a longitudinally slit endless hollow profile having two abutting edges that lie against one another from a metal strip coated with paint on at least one side by means of rolling deformation. Production of a longitudinal weld seam takes place by means of welding the two abutting edges to one another, and introduction of profilings into the welded hollow profile takes place to produce the hollow profile.
Also, in accordance with the method, the longitudinal weld seam is externally ablated, particularly scraped off, to produce a smooth outer weld seam surface, and the outer profile surface is coated, particularly in strip form, in the region of the outer weld seam surface and the adjacent regions, with paint by means of imprinting the paint.
Advantageous further aspects of the invention are discussed below.
Other objects and features of the invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It is to be understood, however, that the drawings are designed as an illustration only and not as a definition of the limits of the invention.
In the drawings,
Turning now in detail to the drawings and in particular
Sash bars 5 can have different hollow profile cross-section shapes. A common hollow profile sash bar 6 (
In this connection, the production of hollow profile 6, particularly hollow profile sash bar 6 according to the invention, takes place in a method, preferably a continuous method, by means of rolling deformation and longitudinal welding, from a metallic flat band material, i.e. a metal band 15 (
After subsequent drying of the paint in a drying device through which the coated metal band 15 is passed continuously, for practical purposes, it is practical if the coated metal band 15 is wound up again, and then cut into multiple longitudinal strips 16 that lie parallel to one another. It is practical if this process is also done continuously, in a cutting device. Later, the longitudinal edges 16a on both sides of the metal strips 16 form the two abutting edges 12 that extend longitudinally.
In a known device for bending by rollers (not shown) that follows the cutting device, a metal strip 16, in each instance, is now continuously deformed into an endless hollow profile 17 having a longitudinal slit, in such a manner that the two abutting edges 12 abut one another, and the side of the metal strip 16 coated with paint forms the outer profile surface 6b. Rolling deformation takes place in known manner, using a pair of bending rollers (not shown) that are disposed one behind the other in a conveyance direction in which the metal strip 16 is conveyed. In this connection, the metal strip 16 is passed through between the two bending rollers of a bending roller pair, in each instance. In this connection, the one bending roller has a circumferential surface curved in concave manner, and the other bending roller has a circumferential surface curved in convex manner, whereby the circumference surfaces are coordinated with one another and the curvature increases from one pair of rollers to the next pair of rollers in such a way that the metal strip is gradually bent to form the longitudinally slit endless hollow profile 17.
It is practical if the endless hollow profile 17 has an essentially flat-oval, elliptical cross-section, whereby just like in the subsequent hollow profile sash bar 6, the expanse of the endless pipe 17 in the width direction 13 is already less than in the height direction 18. As a result, the main axis 19 of the elliptical cross-section is parallel to the height direction 18, and a secondary axis 20 is parallel to the width direction 13. The endless hollow profile 17 thus has two main zeniths 21 that lie opposite one another in the direction of the main axis 19, and two secondary zeniths 22 that lie opposite one another in the direction of the secondary axis 20. In this connection, the profile wall 6a is rounded off in the region of both zeniths 21, 22 but at least in the region of one, preferably both of the main zeniths 21, particularly configured in arc shape. In particular, the outer profile surface 6b has a radius of 2 mm to 4 mm, preferably 3 mm, in the main zeniths 21. The two main zeniths 21 furthermore demonstrate a greater curvature than the secondary zeniths 22. Also, the endless hollow profile 17 is furthermore preferably configured symmetrical to the center plane 14, and has a longitudinal expanse in the direction of the longitudinal axis 11. It is practical if the two abutting edges 12 and thus also the longitudinal weld seam 7 are furthermore disposed at one of the two main zeniths 21.
In a known welding device used in the device according to the invention (not shown), which follows the rolling and bending device, the two abutting edges 12 that abut one another are welded to one another by means of producing the longitudinal weld seam 7. Welding takes place, for example, by means of laser welding or induction welding.
Because, as has already been explained, the paint comes off outer profile surface 6b in the region around longitudinal weld seam 7, and weld seam 7 projects outward beyond profile wall 6a, it is provided, according to the invention, to ablate longitudinal weld seam 7 on the outside, so that the material of longitudinal weld seam 7 no longer projects outward beyond profile wall 6a, and outer profile surface 6b in this region is completely smooth and planar, and to subsequently coat the resulting paint-free region of outer profile surface 6b with paint.
The weld seam ablation device 23 (
The three blades 25 are disposed distributed around the opening 26, whereby they project into the opening 26, radially with reference to the axis of rotation 27, in other words project beyond an opening wall surface 29 that, delimits the opening 26 radially toward the inside, so that the longitudinal weld seam 7 can be scraped off by means of the blades 25. In this connection, the three blades 25 are preferably disposed uniformly distributed about the axis of rotation 27, in other words seen in the circumferential direction of the opening 26. Furthermore, the blades 25 preferably have an identical spatial shape. In this connection, it is practical if a blade cutting edge 30 has a concave progression, particularly an arc-shaped, concave progression curved around the axis of rotation 27. Furthermore, the blade cutting edge 30 preferably extends in a plane perpendicular to the transport direction 28.
In order to scrape off the longitudinal weld seam 7, one of the blades 25 is always disposed in such a manner that it stands in engagement with the endless hollow profile 17, while this profile 17 is being passed through the opening 26. In particular, the endless profile 17 is passed through the opening 26 in such a manner that the longitudinal weld seam 7 faces upward, so that the top blade 25 is always in engagement with the endless hollow profile 17. Because the endless hollow profile 17 performs a movement relative to the blade 25 in the transport direction 28 as it passes by the blade 25, and the blade 25, at the same time, performs a movement relative to the endless hollow profile 17, perpendicular to the transport direction 28, because of the rotational movement about the axis of rotation 27, the longitudinal weld seam 7 is cut off, i.e. scraped off from the endless hollow profile 17 on the outside, in other words starting from the outer profile surface 6b, by means of a drawing cut. In this connection, the longitudinal weld seam 7 is ablated.
In order to adapt the height of the blade 25 that is in engagement, in each instance, to the height of the endless profile 17, the blade holder 24 is preferably adjustable in height. The height of the blade 25 has to be set in such a way that the longitudinal weld seam 7 is scraped off to such an extent that the longitudinal weld seam 7 no longer projects beyond the profile wall 6 on the outside, and that a smooth outer weld seam surface 7a (
The weld seam ablation device 23 is followed by a known profiling device (not shown) used in the device according to the invention in which the endless hollow profile 17, which has been welded in the longitudinal direction, is profiled in such a manner that it is given the desired cross-section shape, i.e. the cross-section shape described above, of the hollow profile sash bar 6 to be produced. For this purpose, it is practical if the profiling device has multiple profiling rollers, in known manner. In particular, the endless hollow profile 17 is profiled in such a manner that the two main zeniths 21 are flattened in order to form the face walls 9, and the two secondary zeniths 22 are flattened to form the side walls 8. Furthermore, the concave transition walls 10 are pressed in.
According to the invention, the hollow profile sash bar 6 is now subsequently coated with paint, once again, after profiling, as already explained above, specifically only in a strip-shaped paint-free region on the longitudinal weld seam 7 and around the longitudinal weld seam 7, where the paint came off during welding. This strip-shaped, paint-free, planar region consequently lies on the face wall 9 that has the longitudinal weld seam 7.
For this purpose, a paint application device 31 of the device according to the invention follows the profiling device. The paint application device 31 has a paint container 32 containing the paint to be applied, a paint pick-up roller 33 for picking the paint up from the paint container and transferring the paint to a stencil roller 34, a squeegee device 35 for stripping off excess paint from the stencil roller 34, and an application roller 36 for applying the paint to the hollow profile sash bar 6.
In this connection, the hollow profile sash bar 6 is passed through the paint application device 31 in a transport direction 42 that preferably lies parallel to the longitudinal axis 11 and the transport direction 28. The paint pick-up roller 33 can be driven to rotate about an axis of rotation 33a that is preferably perpendicular to the transport direction 42, preferably horizontal, in a direction of rotation 33b, and is disposed in such a manner that it is immersed into the paint container 32 and thereby picks up paint. The stencil roller 34 can also be driven to rotate about an axis of rotation that is perpendicular to the transport direction 42, preferably horizontal, but in the opposite direction of rotation 34b relative to the paint pick-up roller 33. In this connection, the paint pick-up roller 33 and the stencil roller 34 roll on one another in such a manner that the paint picked up by the paint pick-up roller 33 is transferred to the stencil roller 34.
The stencil roller 34 furthermore has at least one groove (not shown) in its circumference surface 37, which groove runs in the circumference direction. The groove establishes the amount of paint and the width of the paint strip that is applied to the hollow profile sash bar 6.
For this purpose, the excess paint is stripped from the circumference surface 37 by means of the squeegee device 35, so that only the paint in the groove remains on the circumference surface 37. It is practical if the groove has a depth, in other words a radial expanse, of 0.1 mm to 0.3 mm, preferably 0.15 mm to 0.2 mm. Furthermore, it is practical if the groove has a width, in other words an expanse parallel to the axis of rotation 34a, of 2 mm to 4 mm, preferably 2.5 mm to 3 mm. This paint that remains in the groove is then transferred from the stencil roller 34 onto the application roller 36, for which purpose the stencil roller 34 and the application roller 36 roll on one another.
The application roller 36 can also be driven to rotate about an axis of rotation 36a that is perpendicular to the transport direction 42, preferably horizontal, but in the opposite direction of rotation 36b relative to the stencil roller 34. According to a preferred embodiment of the invention, the application roller 36 furthermore has a mantle wall 38 that consists of rubber. In particular, the mantle wall 38 consists of silicone rubber or PU (polyurethane). Furthermore, the material of the mantle wall 38 preferably has a hardness of 20 to 80 Shore-A, preferably 70 to 80 Shore-A.
The particular advantage of the mantle wall 38 made of rubber as compared with a mantle wall made of metal, particularly steel, lies in the different degrees of hardness that can be used, and in the function of balancing out slight depressions in the material to be imprinted.
The paint is transferred to the application roller 36 in such a manner that the application roller 36 has a paint strip having a predetermined width, in other words an expanse parallel to the axis of rotation 36a of the application roller 36, on its smooth, non-profiled circumference surface 40. This paint strip is applied, particularly imprinted, by means of the application roller 36 and from it onto the hollow profile bar 6. For this purpose, the hollow profile bar 6 is guided past the application roller 36 with the face wall 9 that has the longitudinal weld seam 7 facing the application roller 36, particularly guided through with the corresponding face wall 9 facing upward, underneath the roller. In this connection, the application roller 36 rolls on the corresponding face wall 9, whereby it exerts a predetermined pressure on this wall 9, so that the paint is imprinted in strip form, from the application roller 36 onto the outer weld seam surface 7a and the outer profile surface 6b adjacent to the outer weld seam surface 7a. In this connection, the hollow profile sash bar 6 is supported, in suitable manner, by means of corresponding counter-pressure means (not shown).
In this connection, the paint strip that is imprinted onto the face wall 9 by means of the application roller is dimensioned, in terms of width, such that it covers the outer weld seam surface 7a and the region of the outer profile surface 6b from which the paint that was previously applied came off during welding. In this way, a closed paint layer is formed on the entire outer profile surface 6b of the hollow profile bar 6. In this connection, the amount of the paint applied by means of the application roller 36 and thus the coating thickness is particularly determined by the depth of the groove. For practical purposes, this depth is established in such a manner that the coating thickness in the region of the paint strip essentially corresponds to the coating thickness in the region of the remainder of the profile wall 6. In this way, a homogeneous coating thickness over the entire outer profile surface 6b is guaranteed, thereby resulting in uniform coloring.
It is practical if the device according to the invention furthermore has a device for cutting the endless hollow profile sash bar 6 into hollow profile sash bars 6 having a predetermined length, for example for use as a sash bar 5.
In the method according to the invention, it is advantageous that hollow profiles 6 of any type, having a very slight wall thickness, can be produced by means of rolling deformation. The wall thickness of the hollow profile sash bar 6 that is produced preferably amounts to 0.35 mm to 0.4 mm, preferably 0.37 mm to 0.4 mm. In this way, tremendous material costs are saved in comparison with production by means of extrusion. Furthermore, the hollow profile bar 6 produced according to the invention has a homogeneous paint coating on its entire outer profile surface 6b. In this connection, coating has taken place, in all regions, by means of imprinting the paint, i.e. printing with paint. In this coating method, significantly less paint is required than in powder-coating, and this savings in paint in turn saves costs. Furthermore, a clearly smoother surface is obtained. Because of the high material costs, the method according to the invention is cost-effective despite the two additional method steps.
In this connection, it was discovered, within the scope of the invention, that ablation of the weld seam by means of the drawing cut, in particular, using suitable means, especially the oscillating blade 25, is particularly advantageous because this process yields a sufficiently smooth outer weld seam surface 7a in a single work step with damp cleaning, without any subsequent machining, to which the imprinted paint permanently adheres. Even during profiling of the endless hollow profile 17, the weld seam 7 no longer bulges up, so that the planar outer weld seam surface 7a is maintained. This result was not easily predictable. As a result, a particularly advantageous selection was made to the effect that ablation already takes place ahead of profiling.
Furthermore, the hollow profile sash bar 6 according to the invention does not have any profile retractions that could be disruptive when connecting multiple profiles with one another by inserting them into one another.
Of course, it also lies within the scope of the invention to first wind up the metal band 15 after coating it with paint and subsequently drying it, and to process it further later, or to cut it into the metal strips 16 and first wind these up. These alternatives can also take place in devices specifically provided for this purpose, separate from the device according to the invention. Alternatively, metal strips 16, particularly pre-finished metal strips, can be used, and these strips can be directly coated with paint.
Furthermore, the production process as a whole or the individual steps can also take place discontinuously.
Although only a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2008 050 541.2 | Oct 2008 | DE | national |
