Patent Grant
10858877
This application is the U.S. National Stage of International Application No. PCT/EP2017/059806 filed on Apr. 25, 2017, which claims priority to European patent application no. 16 167 098.9 filed on Apr. 26, 2016.
The present invention relates to an insulating strip for door, window or façade elements, a composite profile for door, window or façade elements comprising such an insulating strip, and a method for finishing manufacturing of a roll-in head of an insulating strip for door, window or façade elements.
Insulating composite profiles for door, window or façade elements and the like are well known. Such an insulating composite profile usually comprises two profiles thermally insulated and mechanically connected by one or more insulating strips. Such an insulating strip is made of plastic material with low thermal conductivity to provide good thermal insulation of the two profiles. The insulating strip can be connected to the profiles by so-called rolling-in of roll-in heads of the insulating strip into corresponding grooves of the profiles. This roll-in technique is exemplary shown in FIGS. 1 to 3 of WO 84/03326 A1.
The shear strength of such a roll-in connection in the longitudinal direction of the composite profile is critical, especially for larger door, window or façade elements with side lengths of 1.5 m or more.
DE 36 33 932 C1 and DE 36 33 933 A1 disclose insulating strips comprising metal elements embedded in plastic bodies of the insulating strips for providing a form-fit connection with metal profiles connected to the insulating strips.
DE 29 37 454 A1 and DE 39 39 968 A1 disclose a composite profile with an insulating strip comprising a metal wire or a metal sheet embedded in a plastic body of the insulating strip for increasing shear strength between the insulating strip and the metal profiles.
EP 0 085 410 A2 discloses insulating strips comprising wires, strips or foils for increasing shear strength of composite profiles which could be made of metal having a low melting point (lower than that of the metal profiles).
EP 0 032 408 A2, EP 2 045 430 A1, CH 354 573, DE-AS 25 52 700 (family GB 1 523 676), DE-OS 28 30 798, and DE 37 42 416 A1 disclose further techniques to increase shear strength of composite profiles for door, window or façade elements.
DE 32 36 357 A1 discloses a composite profile for door, window or façade elements comprising an insulating strip with a metal layer on an end of the insulating strip. A surface of the groove facing the metal layer may comprise a knurling pattern.
In one aspect of the present teachings, an improved technique for ensuring high shear strength in composite profiles for door, window or façade elements is disclosed.
A metal sheet can be disposed on a least a part of a surface of a roll-in head of an insulating strip. The shear strength with respect to the roll-in head and the metal profile is increased by surface variations like perforations and flaps provided in the metal sheet.
The strip body and the roll-in head of the insulating strip are usually formed integrally, e.g., by extrusion, but assembly from different parts is possible, too, e.g. by gluing, welding etc. The metal sheet can be mounted on the roll-in head after the extrusion because the sheet does not have to be fully embedded in the roll-in head.
A firm fit of the metal sheet on the roll-in head can be provided by surface variations of the metal sheet in form of protrusions into the surface of the roll-in head. Such protrusions can be achieved by pressing the perforations and/or the flaps into the material of the roll-in heads.
Additional features and advantages will become apparent upon reviewing the following detailed description of exemplary embodiments with reference to the appended figures.
The composite profile 1 comprises two profiles 2. The two profiles 2 are disposed opposite to each other in a height direction y, which is perpendicular to the longitudinal direction z, and are spaced apart by a distance d in the height direction y. The distance d can be in a range of 1 cm to 25 cm. A wall thickness t of the profiles 2 can be in a range from 1 mm to 20 mm.
The profiles 2 are made of a metal material such as aluminium. The metal material of the profiles 2 usually has a tensile strength in a range with a lower limit of 80 N/mm2 for relatively pure aluminium and an upper limit of 600 N/mm2 for high strength aluminium alloys, and a yield strength in a range with a lower limit of 30 N/mm2 for relatively pure aluminium and an upper limit of 500 N/mm2. A typical value for a typical aluminium alloy used for composite profiles for window, door or façade elements such as EN AW 6060, EN AW 6061, EN AW 6063 are a tensile strength of 180-260 N/mm2 and a yield strength of 160-230 N/mm2.
The profiles 2 are connected to each other by two insulating strips 3. The insulating strips 3 are spaced apart by a distance w in a width direction x, which is perpendicular to the height direction y and the longitudinal direction z. The distance w can be in a range of 1 cm to 20 cm. A height h of the insulating strips 3 in the height direction y corresponds essentially to the distance d between the profiles 2.
Each of the insulating strips 3 comprises a strip body 4. A thickness of the strip body 4 in a region roughly in the middle between the two profiles 2 in the height direction y is in a range, for example, from 1 mm to 10 mm. The strip body 4 is made of a plastic material with low thermal conductivity λ less than or equal to 1 W/(m K), or preferably to 0.1 W/(m K) such as PA66GF25.
Each of the insulating strips 3 comprises two roll-in heads 5. The roll-in heads 5 are formed at longitudinal edges of the strip body 4 in the height direction y. The roll-in heads 5 are formed integrally with the strip body 4 and are made of the same material as the strip body 4.
The roll-in heads 5 are dovetail-shaped in the cross-section shown in
The cross-section of each roll-in head 5 is essentially trapezoidal. The short basis being the shorter one of the two parallel sides of the trapezoidal shape is integrally connected to the strip body 4 in the height direction y. The long basis being the longer one of the two parallel sides of the trapezoidal shape is located on the opposite side and faces the profile 2, to which the roll-in head 5 is connected, in the height direction y. The long basis is located at an outer edge of the insulating strip 3 in the height direction y. The legs of the trapezoidal shape being the lateral, non-parallel sides of the trapezoidal shape diverge in the width direction x along the height direction y from the strip body 4 towards the profile 2. The angles between the legs and the long basis are acute angles (<90°). The angles between the legs and the short basis are obtuse angles (>90°).
The dovetail-shaped cross-section of the roll-in head 5 is tapered in the height direction y from the profile 2 towards the strip body 4. In other words, the dovetail-shaped cross-section of the roll-in head 5 widens along the height direction y from the strip body 4 towards the profile 2. A thickness of the roll-in head 5 in the width direction x increases along the height direction y from the strip body 4 towards the outer edge of the insulation strip 3 facing the profile 2.
One of the two roll-in heads 5 is inserted into a groove 6 of the one of the two profiles 2 in
Each of the grooves 6 is delimited by a hammer (crimpable flange) 7 and a counterpart 8. A free end 9 of the hammer 7 in the height direction y is spaced apart from the counterpart 8 in the width direction x in an unassembled state of the composite profile 1 such that the roll-in head 5 can be inserted into the groove 6. After the roll-in head 5 has been inserted into the groove 6, the free end 9 of the hammer 7 is bent (pushed) towards the roll-in head 5 and the counterpart 8 such that the free end 9 presses the roll-in head 5 against the counterpart 8 and into the groove 6, thereby crimping the roll-in head 5 between the hammer (crimpable flange) 7 and the counterpart 8. The roll-in head 5 is thus form-fit (friction-fit) in the groove 6, whereby the insulating strip 3 is connected with (engaged or held by) the profile 2. Before bending the free end 9 of the hammer 7, there is a clearance between the roll-in head 5 and the corresponding groove 6, which allows the roll-in head 5 to be inserted into the groove 6 along the longitudinal direction z.
As shown in
A width u of the roll-in head 5 in the width direction x at the distal outer edge side of the dovetail shape is in a range of 2 mm to 10 mm. A height s of the roll-in head 5 in the height direction y is in a range from 1 mm to 10 mm.
A metal sheet 13 covers the three surfaces 10, 11, 12 of the roll-in head 5. The metal sheet 13 is made of a metal material such as steel or a high-strength aluminium alloy with a tensile strength in a range of 300 N/mm2 to 2000 N/mm2 or higher, and a yield strength in a range of 150 N/mm2 to 1000 N/mm2 or higher. In any case, the tensile strength of the metal material of the metal sheet 13 is selected to be higher than the tensile strength of the metal material of the profiles 2, and the yield strength of the metal material of the metal sheet 13 is selected to be higher than the yield strength of the metal material of the profiles 2. A thickness of the metal sheet 13 is in a range from 0.05 mm to 1 mm.
The metal sheet 13 is bent around the two transition edges 14, 15 between the first surface 11 and the second surfaces 10, 12 of the roll-in head 5. The metal sheet 13 covers the three surfaces 10, 11, 12 of the roll-in head 5. The metal sheet 13 does necessarily cover the entire second surfaces 10, 12. The metal sheet 13 may cover a part of each of the second surfaces 10, 12, which extends from the corresponding transition edge 14, 15 towards the strip body 4 over a distance in a range from 1 mm to 10 mm. The metal sheet 13 is pressed onto the roll-in head 5 and extends on the roll-in head 5 along the longitudinal direction z.
An outer surface of the metal sheet 13 facing away from the roll-in head 5 is in contact with surfaces of the groove 6, the hammer 7, and the counterpart 8, respectively, when the roll-in head 5 in mounted in the groove 6 in a rolled-in state. The outer surface of the metal sheet 13 is pressed onto the surfaces of the groove 6, the hammer 7, and the counterpart 8, respectively, due to the pressure of the hammer 7 onto the roll-in head 5 and the metal sheet 13.
The outer surface of the metal sheet 13 comprises a knurling pattern 16. A depth of grooves of the knurling pattern 16 is in a range from 0.01 mm to 2.0 mm, preferably 0.01 mm to 1.0 mm or 0.05 mm to 2.0 mm or 0.1 mm to 0.7 mm or 0.2 mm to 0.5 mm or 0.5 mm to 2.0 mm or 1.0 mm to 2.0 mm. The grooves of the knurling pattern 16 extend essentially perpendicular to the longitudinal direction z along the outer surface of the metal sheet 13. The grooves of the knurling pattern 16 have a width in the longitudinal direction in a range from 0.1 mm to 10 mm. The knurling pattern 16 can be formed on the outer surface of the metal sheet 13 before the metal sheet 13 is disposed on the roll-in head 5. The knurling pattern 16 can be formed by using a knurling wheel. Preferably, peaks of the knurling wheel are sharp. Preferably, a width of the peaks of the knurling wheel in a circumferential direction is in a range from 0.1 mm to 0.5 mm, or in a range from 0.1 mm to 0.2 mm. The knurling pattern 16 enhances shear strength between the outer surface of the metal sheet 13 and the surfaces of the groove 6, the hammer 7, and the counterpart 8, respectively, that are in contact with the metal sheet 13.
The metal sheet 13 comprises holes 17 formed by clinching and/or perforation. The holes 17 are formed after disposing the metal sheet 13 on the roll-in head 5. The holes 17 penetrate the metal sheet 13. The holes 17 are essentially circular.
The holes 17 can be formed using a perforation cutter. A width of peaks of the perforation cutter in a direction perpendicular to a cutting direction can be in a range from 0.05 mm to 10 mm, or in a range from 0.1 mm to 1.0 mm. A penetration depth of peaks of the perforation cutter into the metal sheet 13 and the surface of the roll-in head 5 can be in a range with a lower limit of 0.05 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, or 1.0 mm and an upper limit of 2 mm or more.
The metal sheet 13 comprises flaps 18 formed along the transition edges 14, 15 of the roll-in head 5 in the longitudinal direction z. Each flap 18 comprises two parallel longitudinal cutting edges 19 extending along the longitudinal direction z and one transverse cutting edge 20 perpendicular to the longitudinal cutting edges 19. The term “parallel” in this context covers a parallel arrangement and allows variations of to 20°, 5°, 1°, or 0.1° of an angle between the two longitudinal cutting edges 19. The term “perpendicular” in this context covers a perpendicular arrangement and allows variations of up to 20°, 5°, 1°, or 0.1° of an angle between the transverse cutting edge 20 and each of the longitudinal cutting edges 19 One of the longitudinal cutting edges 19 of each of the flaps 18 formed along each of the transition edges 14, 15 is formed in a part of the metal sheet 13 covering the corresponding one of the second surfaces 10, 12 adjacent to the corresponding transition edge 14, 15. The other one of the longitudinal cutting edges 19 is formed in a part of the metal sheet 13 covering the first surface 11. The transverse cutting edge 20 extends along the metal sheet 13 across the corresponding one of the transition edges 14, 15. The transverse cutting edge 20 is connected to ends of the longitudinal cutting edges 19 of the flap 18 on one side or the other side in the longitudinal direction z. A length of the transverse cutting edge 20 is in a range from 1 mm to 10 mm. A length of each of the longitudinal cutting edges 19 is in a range from 1 mm to 10 mm. A distance between flaps 18 adjacent along each of transition edges 14, 15 in the longitudinal direction z is in a range from 5 mm to 30 mm.
The side of each flap 18 in the longitudinal direction z, on which the transverse cutting edge 20 is connected to the longitudinal cutting edges 19, alternates for any two flaps 18 adjacent in the longitudinal direction z along each of the transition edges 14, 15. Any two adjacent flaps 18 along one of the transition edges 14, 15 are symmetric to each other. The transverse cutting edges 20 are disposed on two sides of the two adjacent flaps 18 in the longitudinal direction z that either face each other or are opposite to each other.
The flaps 18 are pressed into the plastic material of the of the roll-in head 5 along the transition edges 14, 15 on the sides of the flaps, on which the transverse cutting edges 20 are connected to the longitudinal cutting edges 19, after disposing the metal sheet 13 on the roll-in head 5. The transverse cutting edges 20 of the flaps 18 pressed into the plastic material of the roll-in head 5 provide form-fit and high shear strength between the metal sheet 13 and the roll-in head 5. A protrusion depth of the transverse cutting edges 20 into the plastic material can be in the same range as the protrusion depth p of the holes 17. High shear strength in both directions along the longitudinal direction z is provided because the transverse cutting edges 20 are formed on alternating sides of the flaps 18 in the longitudinal direction z, i.e., alternating sides of the flaps 18 are pressed into the plastic material of the roll-in head 5.
Each part of the metal sheet 13 covering one of the surfaces 10, 11, 12 of the roll-in head 5 comprises two lines of holes 17 extending in the longitudinal direction z.
Each of
The holes 17 do not have to be arranged in the above patterns but can be arranged in different patterns or can be arranged randomly. Each of the parts of the metal sheet 13 covering one of the surfaces 10, 11, 12 of the roll-in head 5 may comprise the same pattern of holes 17 or may comprise a different pattern.
Not all parts of the metal sheet 13 covering one of the surfaces 10, 11, 12 must comprise the holes 17. Only one or only two of the parts may comprise the holes 17. The metal sheet 13 may comprise the flaps 18 but not the holes 17. The metal sheet 13 may comprise the holes 17 but not the flaps 18.
The flaps 18 do not necessarily have to be disposed along the transition edges 14, 15. Each of the parts of the metal sheet 13 covering one of the surfaces 10, 11, 12 of the roll-in head 5 may comprise flaps 18.
The outer surface of the metal sheet 13 facing away from the roll-in head 5 does not necessarily comprise the knurling pattern 16. The inner surface of the metal sheet 13 facing the roll-in head 5, which is in contact with the surfaces 10, 11, 12 of the roll-in head 5, may comprise a knurling pattern. The grooves of the knurling pattern on the inner surface and/or the outer surface of the metal sheet 13 can extend obliquely with respect to the longitudinal direction z.
As described above, the dovetail-shaped cross-section of the roll-in head 5 widens along the height direction y from the strip body 4 towards the profile 2. A (first) thickness a2 of the roll-in head 5 at a distal outer edge of the insulating strip 3 facing the profile 2 is larger than a (second) thickness a1 of the roll-in head 5 at the transition from the roll-in head 5 to the strip body 4. The thickness a2 of the roll-in head 5 at the distal outer edge can be in a range with a lower limit of 1.2 times the thickness a1 of the roll-in head 5 at the transition from the roll-in head 5 to the strip body 4, 1.5 times the thickness a1 of the roll-in head 5 at the transition from the roll-in head 5 to the strip body 4, or 1.8 times the thickness a1 of the roll-in head 5 at the transition from the roll-in head 5 to the strip body 4 and an upper limit of 2 times the thickness a1 of the roll-in head 5 at the transition from the roll-in head 5 to the strip body 4 or 4 times the thickness a1 of the roll-in head 5 at the transition from the roll-in head 5 to the strip body 4.
The bases and/or the legs of the essentially trapezoidal cross-section of the roll-in head 5 can be straight lines or can be curved or recessed or the like. The bases and/or the legs can, e.g., include one or more recesses and/or notches.
The cross-sectional shape of the roll-in head 5 can be different from the shape shown in
Although not shown in
The corners of the cross-sectional shapes of the roll-in heads can be rounded.
The metal material of the profiles 2 has a lower tensile strength than the metal material of the metal sheet 13. Therefore, surfaces of the groove 6, the hammer 7, and/or the counterpart 8, respectively, can be deformed by the pressure of the hammer 7 onto the roll-in head 5 and the metal sheet 30, when the roll-in head 5 is rolled in in the groove 6, thereby increasing shear strength. The metal material of the profiles 2 can flow into the knurling pattern 16, the holes 17 and/or the flaps 18 thereby increasing shear strength.
A flux of material in horizontal and/or vertical direction can be controlled depending on the way of perforating and/or clinching the metal sheet 13.
A shear strength of the thermally insulating composite profile 1 of equal to or larger than 70 N/mm can be achieved with the insulating strips 3.
The present disclosure is not limited to the embodiments described above. Features of the different embodiments can be combined and further modification can be applied.
The metal material of the metal sheet 13 can be selected from a group comprising stainless steel, zinc plated steel, aluminium alloys such as AW 7068 or AW7075, and other metals or alloys. Introducing the roll-in head 5 into the groove 6 is facilitated if the metal material of the metal sheet 13 does not comprise aluminium. The tensile strength of the metal material of the metal sheet can be higher than 500 N/mm2 or can be higher than 700 N/mm2.
The insulating strips 3 can be made of plastic material such as PA, PBT, PA-PBE, PET, PMI, PVC, Polyketone, PP, or PUR. The insulating strips 3 can be made of thermoplastic material.
The insulating strips 3 can comprise reinforcing elements such as glass fibers and/or can be made of bio polymers, which are based on renewable resources. Examples for polymers, which can be based on renewable resources, are PA 5.5, PA 5.10, PA 6.10, PA 6.6, PA 4.10, PA 10.10, PA 11, PA 10.12.
The insulating strips 3 can comprise foamed, cellular, and/or porous plastic material. The material of the insulating strips 3 can be completely or partly foamed. The material of the strip body 4 can be completely or partly foamed. The strip body 4 can comprise a foamed core surrounded by a layer of non-foamed material. The material of the roll-in heads 5 can be foamed or not. The roll-in head 5 can be formed integrally with the strip body 4 or can be formed separately and joined to the strip body 4, e.g., by an adhesive. If the roll-in head 5 and the strip body 4 are formed integrally, they can comprise a common core of foamed material surrounded by a cover on non-foamed material. An insulating strip comprising a core of fine pored, closed-cell plastic material and a surface layer of compact, non-porous plastic material as shown in FIG. 1 of EP 1 242 709 B2 can be used.
The roll-in heads 5 can be made of a different plastic material than the strip body 4.
The cross-sectional shapes of the roll-in heads 5 are constant along the longitudinal direction z except for the recesses caused by and/or receiving the surface variations of the metal sheet 13.
The material of the sheet 13 can have a melting point or melting temperature which is higher than a maximum temperature during a coating or varnishing treatment of the insulating strip 3. The melting point of the material of the sheet 13 may be 400 K, 500 K, 550 K, 600 K, 750 K, 1000 K or higher.
The melting point of the material of the sheet 13 can be at least 50 K (Kelvin), 100 K, 150 K, 200 K, 250 K, 300 K, 500 K or 1000 K higher than a melting point of the plastic material of the insulating strip 3. The melting point of the plastic material of the insulating strip 3 can be, e.g., 533 K for PA 6.6 or 513 K for PA 6.10 or 471 K for PA 11. Further values of melting points of plastic materials can be obtained from literature.
The metal sheet 13 can be joined to the roll-in head 5 by laser welding of the metal sheet 13 to metal elements embedded in the roll-in head 5.
The flaps 18 can be cut into the metal sheet 13 using a laser or a cutting wheel. The flaps 18 can be cut into the metal sheet 13 before or after disposing the metal sheet 13 on the roll-in head 5. Other insulating strips may be used instead of the insulating strips 3 shown in the above embodiments. An insulating strip may comprise more than two roll-in heads 5 and/or may be wider in the width direction x than each of the insulating strips 3 shown in the above embodiments. The profiles 2 may be connected by only one insulating strip.
It is explicitly stated that all features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original disclosure as well as for the purpose of restricting the claimed invention independent of the composition of the features in the embodiments and/or the claims. It is explicitly stated that all value ranges or indications of groups of entities disclose every possible intermediate value or intermediate entity for the purpose of original disclosure as well as for the purpose of restricting the claimed invention, in particular as limits of value ranges.
1. Insulating strip (3) for connecting profiles (2, 2) of a composite profile (1) for doors, windows or façade elements, at least one of the profiles (2, 2) being made of a metal material with a first tensile strength and/or a first yield strength and having at least one roll-in groove (6) for roll-in connection with the insulating strip (3), comprising
a strip body (4) made of an insulating material and extending in a longitudinal direction (z), a roll-in head (5) at a longitudinal edge of the strip body (4), the roll-in head (5) having a cross-sectional shape in a plane (x-y) perpendicular to the longitudinal direction (z) adapted to be inserted into the at least one roll-in groove (6) and having a first thickness (a2) of the cross-sectional shape of the roll-in head (5) towards a distal outer edge of the roll-in head (5) facing the at least one roll-in groove (6) being larger than a second thickness (a1) of the cross-sectional shape of the roll-in head (5) at a transition from the roll-in head (5) to the strip body (4), and a sheet (13) covering at least a part of a surface (10, 11, 12) of the roll-in head (5) and comprising surface variations (16; 17; 18), wherein
the sheet (13) is made of or comprises portions made of a metal material with a second tensile strength and/or a second yield strength higher than the first tensile strength and/or the second yield strength, respectively.
2. Insulating strip (3) for connecting profiles (2, 2) of a composite profile (1) for doors, windows or façade elements, at least one of the profiles (2, 2) being made of an aluminium material having at least one roll-in groove (6) for roll-in connection with the insulating strip (3), comprising
a strip body (4) made of an insulating material and extending in a longitudinal direction (z), a roll-in head (5) at a longitudinal edge of the strip body (4), the roll-in head (5) having a cross-sectional shape in a plane (x-y) perpendicular to the longitudinal direction (z) adapted to be inserted into the at least one roll-in groove (6) and having a first thickness (a2) of the cross-sectional shape of the roll-in head (5) towards a distal outer edge of the roll-in head (5) facing the at least one roll-in groove (6) being larger than a second thickness (a1) of the cross-sectional shape of the roll-in head (5) at a transition from the roll-in head (5) to the strip body (4), and a sheet (13) covering at least a part of a surface (10, 11, 12) of the roll-in head (5) and comprising surface variations (16; 17; 18), wherein
the sheet (13) is made of or comprises portions made of steel.
3. Insulating strip according to aspect 1 or 2, wherein a surface of the sheet (13) facing away from the roll-in head (5) comprises a knurling pattern (16).
4. Insulating strip according to any of the preceding aspects, wherein the strip body (4) is made of a thermoplastic insulating material.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16167098 | Apr 2016 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/059806 | 4/25/2017 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/186722 | 11/2/2017 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20190119973 A1 | Apr 2019 | US |
