Patent Application
20210316513
This patent application claims the benefit under 35 USC 119(b) of German Application No. 10 2020 109 830.8 of Apr. 8, 2020, which is incorporated herein by reference.
The invention relates to a method for producing composite profiles extending in a longitudinal direction, in particular plastic-metal composite profiles connected by positive engagement or form fit, and composite profiles produced using this method, which are suitable in particular for use in demanding construction applications, for example in the construction sector in the production of windows, doors, and façade elements or in equipment construction, scaffolding, housing construction, or in the manufacture of vehicles (ground vehicles, aircraft, watercraft).
Conventional composite profiles are, e.g., plastic-metal composite profiles, the profile parts of which are produced from different materials, which in particular are widely used for the aforementioned different purposes.
In the case of composite profiles that are, for example, widely used in the construction industry, one often utilizes the combination of the respective advantageous properties of plastic and metal, e.g., the good ductility and permanence of metals and the low weight, the good shapeability and the good insulating properties (electrical, thermal) of plastics materials.
Such composite profiles are widely used in the field of metal windows, metal doors, and in façade technology. Typically, easily producible aluminum profiles are connected by plastic profiles in order to produce therefrom façade elements, windows, doors, or other building openings (e.g. ventilation apertures etc.).
The conventional connection technology uses a roll-in technology for connecting the plastic and metal profiles by positive engagement in different versions.
Typically, a plastic profile with so-called roll-in feet is first loosely introduced into a metal profile with a matching geometric receptacle and then are finally fixed by positive engagement by deforming a metallic profile component (so-called “hammer”) by rolling in. The roll-in foot of the plastic profile is then held in positive engagement by the metallic “hammer” and a metallic “anvil”. The metal profile is optionally provided with a surface structure in the region of the receptacle, for example knurled, in order to improve a transmission of force in the region of the positive engagement.
Special solutions are also used, for example the adhesive bonding of plastic profiles as a substance-to-substance or material bond. It should generally be noted that composite profiles for windows and façade applications may constitute safety-related components, which in Germany, for example, are tested for suitability according to DIN EN 14024.
Disadvantages of the previously established method for producing composite profiles for windows, door, façades, namely rolling plastic profiles (e.g. extruded profiles made from PA66 GF25 into extruded aluminum profiles) into metal profiles:
problems when threading or inserting the plastic profiles into the corresponding grooves of the aluminum profiles, for example due to superficial accumulations of dirt, burrs, dimensional deviations or fluctuations;
higher (cost) expenditure to increase the shear strength of the plastic-metal connection, for example by knurling the aluminum profiles, by introducing into the plastic profiles metal wires that are conducive to shear strength;
limited ability to improve the torsional rigidity in existing composite designs;
fluctuating strength of the plastic-metal connection due to wear to the roll-in systems, geometry deviations, and dimensional fluctuations of the joining partners, aging phenomena of the materials (moisture, heat);
a continuous 100% inspection for quality assurance is not possible in the roll-in method;
limited freedom of design or unpleasant appearance due to visible marks from knurling/rolling-in;
little flexibility in the method to, for example, comply with requirements of the customer or legislation for increased thermal insulation, e.g. reduction of thermal transition (Uf) values, to achieve energy savings targets.
The different problems stated above are addressed in the prior art in a variety of ways.
In the journal Kunststoffe in Volume 1/2018, beginning on p. 29, a concept for connecting plastic and metal profile segments by positive engagement for the production of composite profile segments for window/door/façade applications is described using a short profile sample. Here, the metal part is roughened or structured by means of a laser beam in order to produce a multiplicity of fine undercuts, which then form a so-called adhesive base for a plastic profile. The plastic component is connected to the metal part. The plastic is then superficially melted by the metal component being heated by means of a laser beam or inductively heated, and pressed into the structure of the metal part. The article shows a short profile sample, clearly connected by form fit or positive engagement, of a length that corresponds roughly to the width of a hand, but does not teach how the plastic is superficially melted or how a longer composite profile, for example of several meters, can be produced. The costs of such a laser structuring of the aluminum component are relatively high, which is due to the low surface speeds of the laser structuring and typically high acquisition and maintenance costs. This is in conflict with the requirement of an economical joining process.
EP 1 510 383 A2 describes a guidance rail, produced by injection moulding, made of different materials, among other things thermoplastic materials. Alternatively, further components can be connected at points by substance-to-substance bond by means of ultrasound.
The pressing or clipping of metal profiles or strips into or onto plastic profiles, wherein no thermal energy is added and a composite component is created directly by way of a positive engagement or cold deformation, is described in WO 2017/186722 A1 and also previously in DE 32 36 357 A1. Here, the partial covering of plastic profiles is achieved by metallic bands.
In accordance with an embodiment of the invention, an economical method for producing composite profiles of the kind described at the outset is provided, which in particular creates a permanent, solid bond of the profile parts, wherein the obtained composite profile moreover has good properties for use in technically demanding construction applications. These construction applications include, in particular, applications in the construction sector, primarily in the production of window, door, and façade profiles, and window, door, and façade elements produced therefrom.
In accordance with an embodiment of the invention, a method for producing a composite profile extending in a longitudinal direction is provided, comprising providing a first profile part extending in a longitudinal direction, made from a first plastics material, with a profile region, wherein the profile region of the first profile part is produced from a second plastics material that is thermally plasticizable at a first temperature T1,
providing a second profile part extending in a longitudinal direction, which is produced from a material that is not thermally plasticizable at the first temperature T1, wherein the second profile part has a receiving structure formed along the longitudinal direction of the second profile part, to which the profile region of the first profile part is connectible by positive engagement,
bringing the profile region of the first profile part into contact with the receiving structure of the second profile part,
plasticizing the second plastics material of the profile region of the first profile part by heating to the first temperature T1 and
deforming the plasticized second plastics material of the profile region of the first profile part while forming a positive engagement between the profile region of the first profile part and the receiving structure of the second profile part, wherein the receiving structure has a geometry that remains substantially unchanged during formation of the positive engagement.
Thus, the composite profile to be produced in accordance with the invention comprises at least two profile parts, which each extend in a longitudinal direction and differ from one another in their material composition. A first profile part is produced from a first plastics material and comprises a profile region made of a second plastics material that is thermally plasticizable at a first temperature T1. A second profile part is produced from a material that is not thermally plasticizable at the first temperature T1, for example from metal.
These profile parts are connected to one another in their longitudinal direction according to the method in accordance with the invention, wherein the achieved positive engagement or form fit perpendicular to the longitudinal direction can also be configured to be shear-resistant in the longitudinal direction if necessary.
The method in accordance with the invention enables not only an economical production of the composite profile, but also ensures a high level of process security that the conventional roll-in method lacks.
Thus, with the method in accordance with the invention, longer composite profiles can be obtained, for example composite profiles with a length of at least 50 cm or preferably with a length of at least 3 meters. Commercially available composite profiles for metal windows/doors/façades typically have lengths of 5 m to 7.5 m, though different lengths are possible.
It is also possible to produce endless composite profiles (i.e. lengths of several hundred meters), which can then be wound on spools instead of in the form of bar-type goods, provided the profile geometry and the materials allow for the required bend radii.
The positive engagement between the first and the second profile part is preferably of continuous configuration, but may also be regularly or irregularly interrupted.
The connection technology in accordance with the invention is suited in particular for the production of composite components for use in the manufacture of vehicles (railway vehicles, land vehicles, watercraft, and aircraft, etc.), as well as in the manufacture of ventilation systems, plant engineering, and device engineering (stiffening profiles, reinforcing profiles, frame profiles etc.).
In the production of composite profiles for window, door, and façade elements, the first profile part is preferably an insulating profile for thermal separation. Such insulating profiles are generally known under the trade name Insulbar® of the company Ensinger GmbH. These insulating profiles can be produced in many versions, i.e. shapes and materials. The plastic profiles are preferably produced from meltable plastics or plastics materials on the basis of thermoplastic polymers, e.g. polyamides, polyesters, polyolefins, vinyl polymers, polyketones, polyether, and mixtures and blends thereof. Elastomers, in particular thermoplastic elastomers, are also suitable.
The method in accordance with the invention makes it possible, in particular, to continuously connect plastic profile parts to metal profile parts, in particular to aluminum profiles. Here, a positively engaging connection or form fit is produced by one or more profile regions of the first (plastic) profile part being brought into contact with a receiving structure of the second (metal) profile part, for example a groove, and then the second plastics material part of the profile region of the first profile part being plasticized in a zone (joining region) delimited in the longitudinal direction and being mechanically deformed, in particular sunk, under exertion of a pressure, wherein the plasticized second plastics material and the receiving structure of the second (metal) profile part form a positive engagement or form fit, such that, after the second plastics material solidifies, a composite profile with a positively engaging connection extending in the longitudinal direction is obtained.
This process may preferably take place in a continuous manner, i.e., with a continuous longitudinal movement of the profile parts or the composite profile in the process direction (corresponding to the longitudinal direction of the profile).
The connection by positive engagement of material combinations plastic-metal by means of ultrasound is known per se, for example from Saechtling Kunststoff Taschenbuch, 30th Edition from 2007 (ISBN 978-3-446-40352-9), chapter 4.13.1.4 and fig. 4.137F. Here, the method is limited, however, to the introduction of a small metal insert in the form of a threaded bush into a moulded plastic part by application of ultrasound.
DE 32 03 631 A1 mentions the possibility of using an additional material to improve the positive engagement of a metal-plastic composite profile and to press said material into positive engagement-increasing recesses of a receiving groove as part of an ultrasound treatment. However, the prerequisite here is the presence of a connection by positive engagement that is merely improved.
In contrast, in accordance with the invention, a positive engagement as such is produced only through the plasticization and deformation of the second plastics material, such that the method overall can be performed with considerably lower expenditure and lower requirements both for the geometry of the profile region and for the receiving structure. Moreover, the method in accordance with the invention provides a significantly improved freedom of design and, among other things, also with the ability to achieve an improved insulation effect.
In DE 10 2017 107 684 A1 regarding a modular system for plastic profiles, the application of an ultrasonic method for welding plastic components to one another is proposed for producing components with more complex profile cross sections from simple plastic profile shapes. The ability to produce composite profiles with a positively engaging connection of two profile parts is not disclosed.
The plasticization of the second plastics material of the profile region of the first profile part in accordance with the present invention may take place in a variety of ways.
In accordance with one variant of the method in accordance with the invention, the second profile part, in particular a metal profile part, may be preheated or heated to a sufficiently high temperature above temperature T1 in order to effect the plasticization of the second plastics material of the profile region of the first profile part, i.e., in order to thus deliver the heat energy to plasticize the second plastics material of the profile region of the first profile part (subsequently referred to as the melting region of a plastic profile) to a sufficient degree for the subsequent deformation. In particular contact heating, inductive heating, e.g., by means of guiding the metallic profiles along or through inductive coils, infrared irradiation, or heating by applying a flame to the second profile part etc. are suitable for this.
In accordance with a further preferred variant of the method in accordance with the invention, the plasticization is performed by means of sonication, in particular using a sonotrode. This variant is suitable not only for composite profiles in which the second profile part is a metal component, but also for second profile parts that are made of ceramic materials, glass, wood, a thermoplastic plastics materials with a melting point or a glass transition temperature or optionally softening temperature above the first temperature T1 and a thermosetting plastics material.
The receiving structure can be configured in a wide variety of ways in the method in accordance with the invention. According to one variant, the second profile part is configured with a receiving region as a receiving structure extending in the longitudinal direction, said receiving region having the form of a receiving groove. In particular, the receiving groove may extend continuously in the longitudinal direction of the second component.
Furthermore, according to the method in accordance with the invention, the second profile part may be configured with a receiving structure which comprises a plurality of recesses that are arranged flush, in particular one behind the other, in the longitudinal direction of the second profile part, which recesses may be, for example surface structurings and/or surface penetrations and/or surface perforations.
In accordance with the invention, the profile region of the first profile part is preferably configured as a projecting profile region, e.g., as a profile region projecting perpendicularly from a surface of the first profile part. The profile region can, in particular, be configured as an uninterrupted, continuous projection extending in the longitudinal direction of the first profile part, or as a plurality of non-continuous projection segments, arranged one behind the other in the longitudinal direction of the first profile part at a distance from one another, optionally formed in alignment with one another.
The first profile part used in the method in accordance with the invention may be equipped not only with one profile region, but with a further profile region that is also made from the second plastics material. The further profile region typically extends in parallel to the first profile region at a predetermined lateral distance perpendicular to the longitudinal direction of the first profile part.
In this variant of the method in accordance with the invention, a third profile part (as a further second profile part) extending in a longitudinal direction, made of a material that is not thermally plasticizable at the first temperature T1 may be provided, wherein the third profile part has a receiving structure extending in its longitudinal direction. The second or further profile region of the first profile part can then be brought into contact with the receiving region of the third profile part and be plasticized while forming a positive engagement or form fit. This may take place simultaneously with or temporally offset from the first profile region being brought into contact with the receiving region of the second profile part.
The profile region or the profile regions of the first profile part may be produced integrally with the first profile part, for example in one single extrusion operation, wherein, in particular, the first and the second plastics material are then based on the same polymeric material and, in particular, are produced from an identical plastics material.
Alternatively, the profile region(s) may be moulded onto the body, in particular coextruded, extruded on in a subsequent step, welded on, or adhesively bonded on. Here, too, the first and the second plastics material are based on the same polymeric material or are produced from an identical plastics material. Alternatively, different polymeric materials may be used for the production of the profile region(s) on the one hand and the first profile part on the other hand.
This potential variety of materials makes it possible to optimize partial regions of the profiles or the plastic profiles and/or the composite profiles produced therefrom, e.g., with respect to mechanical characteristics (rigidity, strength, impact resistance, elongation at break, dimensional stability, shear strength, shear spring rigidity, creeping tendency etc.), weight, production costs, insulation effect (thermal, electrical, sound etc.), recyclability (material, chemical, thermal), resistance to chemical/physical influences (wind and weather, UV radiation, temperature change, process chemicals, and cleaning agents), paintability (wet paints, powder stoving lacquers, primers), fire protection/flame protection.
In accordance with the invention, in particular flat, band-shaped plastic components can easily be adapted for use as a first profile part in the method in accordance with the invention by the required profile region and optionally further functional elements being connected to said components. The methods suitable for this are known, e.g., extrusion, welding, or adhesive bonding.
Advantages of using long and endless fiber-reinforced composites for producing the first profile part are the superior material properties, especially the increased inherent rigidity, strength (e.g., under tensile, bending, torsional load), and in special cases the improvement of the fire protection properties as a result of temperature-resistant fiber woven fabrics in the profile body.
As already mentioned, according to the method in accordance with the invention, the material that is not thermally plasticizable at the first temperature T1 can be selected from a wide range of materials. This applies not only to the second, but optionally also to the third profile part. In particular, the material that is not thermally plasticizable at the first temperature T1 is selected from a metallic material, in particular based on aluminum or iron, a ceramic material, glass, wood, a thermoplastic material with a melting point or a glass transition temperature above the first temperature T1 and a thermosetting plastics material.
The second profile parts, in particular in the form of metal profiles, of the composite profiles produced in accordance with the invention may also be produced in different geometries and have simple geometric basic forms in cross section (e.g., substantially round, oval, rectangular, square) or more complicated symmetrical or asymmetrical cross sections and optionally different wall thicknesses. For example, an additional structuring may also be provided along the longitudinal direction, for example a periodic or random arrangement of perforations or recesses, or accumulations of material, or deformations, for example by means of knurling, drilling, punching, embossing, or other chemical or physical structuring methods (removal by etching processes or laser treatment).
For example profiles made of rolled stainless steel or extruded profiles of aluminum or aluminum alloys are preferable as second and optionally third profile parts. These profiles are producible in different designs and are commercially available.
Furthermore, in the method in accordance with the invention, the first plastics material for the first profile part and/or the thermally plasticizable second plastics material for the profile region(s) of the first profile part is preferably selected from thermoplastic polymeric materials on the basis of polyamides, polyimides, polyesters, polyolefins, in particular polyethylene and polypropylene, polyketones, vinyl polymers, in particular polystyrene and polyvinylchloride, polyether, in particular polyphenylene ether, polycarbonate, polyphenylene sulfide, and mixtures thereof, in particular polyetherketones, polyetheretherketones, and polyetherimides, as well as copolymers thereof and blends of the above plastics materials. Elastomers, in particular thermoplastic elastomers, are also suitable as the first plastics material.
Overall, the method in accordance with the invention allows for a wide range of materials for the production of the profile parts from a multitude of materials, such that the selection can be tailored specifically to the requirements of the respective application area of the produced composite profiles.
Moreover, in accordance with the invention the first and/or the second plastics material may contain fillers and/or reinforcing substances, which in particular are selected from glass fibers, metal fibers, carbon fibers, plastic fibers, mineral fibers, plant fibers, and mixtures thereof, wherein the fibers are preferably used in the form of short fibers, long fibers, endless fibers, woven fiber fabrics, laid fiber fabrics, or fiber felts.
Further suitable fillers are, e.g., glassy, amorphous, crystalline additives in the form of powders, balls, hollow balls, aggregates, or agglomerates, in particular of glass powder, glass balls, lime, chalk, metal oxides, metal hydroxides, molecular sieves.
Moreover, additives like, for example, flame protection/fire protection agents, thermal/heat/UV/hydrolysis stabilizers, softeners, impact modifiers, expanding agents, glidants and lubricants, colorants, nucleating agents etc. can be used as fillers.
The use of melting adhesives, melting wires (monofilament and coextruded variants), metal wires, foams (cut or extruded foam blocks, foam bands etc.), metal foils (coated or uncoated foils with a single-layer or multi-layer structure) is also possible to be able to functionalize products in a tailor-made manner.
This enables an additional adaptation of the materials used to the requirements of the respective area of application of the composite profiles produced in accordance with the invention.
Particularly preferably are plastic profiles on the basis of polyamide 66 (PA 66), polyamide 6 (PA6), polymer blends of PA66 and polyphenylene ether (PPE), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), acrylonitrile butadiene styrene copolymers (ABS), acrylonitrile styrene acrylate copolymers (ASA), acrylonitrile styrene copolymers (SAN), polyacrylate, for example polymethylmethacrylate (PMMA), polyvinylchloride (PVC), polypropylene (PP), polycarbonate (PC), or polystyrene (PS) with a proportion of glass fibers for reinforcement.
In accordance with a further variant of the method in accordance with the invention, the first profile part is configured to be porous at least in parts, i.e., foamed or filled with porous (porous with open or closed cells) fillers. This increases the heat transfer resistance in the composite profiles and reduces their density. The first profile part may also be configured to be porous as a whole.
The method in accordance with the invention can be performed such that the method steps of bringing the profile region(s) of the first profile part into contact with the receiving structure(s) of the second an optionally the third profile part, the plasticization and the deformation in a zone (joining region) delimited in the longitudinal direction of the profile parts are performed continuously or intermittently. If the first profile part has two profile regions, according to one variant, the bond of the first profile part with the second and the third profile part can thus be produced simultaneously.
The method in accordance with the invention is based on a profile region of the first profile part functioning as a so-called melting element and being plasticized and deformed in contact with a receiving structure of the second profile part, wherein the first and the second profile part are connected to one another by means of a positive engagement or form fit after the second plastics material has solidified.
The plasticization is preferably achieved by introducing ultrasonic vibrations or other high-frequency energy (“high-frequency welding”), or the input of the required amount of heat for plasticizing the profile region (melting element) can also be effected by inductively heating the second profile part. Further, the energy input by means of contact heating with heating elements, heating with open flames, fan heaters or heated gas, infrared radiation, laser radiation is also possible for achieving the plasticization of the second plastics material.
The method in accordance with the invention for producing the composite profile in accordance with the invention is thereby typically carried out such that the first and second profile parts are fed to a joining system and in an intake region of the joining system are oriented relative to one another (setting) in such a way that the respective melting element of the first profile part comes into contact with the associated receiving structure of the second profile part.
The first and second profile parts can be set in this way by, for example, one profile part being inserted or drawn into the other profile part, as is known from the so-called roll-in method. The receiving structure is hereby typically of groove-shaped configuration.
It is also possible, however, to place the one profile part onto the other profile part like a lid. The setting can thereby be facilitated by centering and assembly aids. Functional elements on the part of the first profile part in the form of latching devices, for example snapping hooks, may thereby serve as assembly aids in order to quickly and securely position the initially loosely joined profile parts and make a workpiece able to be handled until the positive engagement is complete. Centering aids on the part of the first profile part as a further functional element can thereby aid in a precise positioning of the profile parts during setting and ensure a correct end position is reached after the formation of the positive engagement.
After the positioning, the first and second profile parts are now transported in their longitudinal direction, which corresponds to the longitudinal direction of the composite profile to be produced, subsequently also called the Z-direction, to a zone (joining region) delimited in the longitudinal direction, said zone being composed of a plasticization section and a holding section following in the Z-direction.
In the plasticization section, according to a preferred embodiment of the method in accordance with the invention, the profile parts are continuously guided in the Z-direction past a sonotrode segment.
In the sonotrode segment, in addition to the sonication, a mechanical pressure perpendicular to the Z-direction is exerted on the two profile parts by way of a contact surface of one or more sonotrodes that abut against a surface of one of the profile parts. A counter bearing must therefore be arranged on the side opposite the sonotrode(s) in order to absorb these forces. The mechanical pressure is thereby preferably produced by the one or more sonotrodes by the contact surfaces thereof being arranged at an angle α relative to the feed direction Z, corresponding to a conveying direction F.
An additional mechanical pressure or contact pressure, in addition to the pressure exerted by the sonotrodes, may be introduced to the two profile parts by additional means, for example by way of pressing rollers, belt drives, spring elements, and/or pressing rails. The speed at which a melting region is then melted off and the profile parts to be joined are brought into their end configuration perpendicular to the Z-direction then arises from the feed speed in the Z-direction and the angle α.
If the contact surface is formed with different angles in one or more sonotrodes, one can, for example, define an average angle α over an entire sonotrode segment, said angle being calculated from the length, measured from the point at the level of the first sonotrode contact, until the final lowering height and the lowering height realized therein is reached. The lowering level is thereby the distance by which the first profile part is melted down or lowered after being brought into contact by the plasticization (of the melting element) and lowering into the end configuration relative to the second profile part.
In accordance with the invention, lowering levels of about 0.3 mm to about 12.0 mm are preferred, lowering levels of about 0.5 mm to about 6.5 mm being particularly preferable.
The joining method may thereby in particular be performed such that a plurality of sonotrode segments are simultaneously in operation to produce a plurality of (offset) positive engagements in one pass. Thus, for example, a first profile part with two profile regions arranged in parallel at a distance from one another, said profile regions forming melting zones, can be connected to two second profile parts simultaneously by way of a respective positive engagement.
In principle, a sonotrode segment may comprise one single sonotrode or a plurality of sonotrodes controlled jointly or separately and lined up in the longitudinal direction Z. The sonotrodes are configured with respect to the arrangement, alignment/tilt, dimensioning, material selection, and power input such that a predetermined melting of the melting element takes place when the profile parts pass through the plasticization section.
The sonotrodes introduce high-frequency ultrasonic vibrations into the profile parts that are to be connected with a positive engagement. The frequency is preferably in the range of about 16 kHz to about 90 kHz, the frequency range is particularly preferably from about 19 kHz to about 45 kHz.
The sonotrodes are preferably installed statically, i.e., during plasticization, after this process, substantially no further movement on the part of the sonotrodes, in particular no raising and lowering movement, takes place, aside from the ultrasonic oscillation. However, it may also be advantageous to use a non-static sonotrode in the method, wherein the contact surface of the sonotrode can then be moved, e.g., both in the longitudinal direction Z and in a height direction Y perpendicular to the longitudinal direction Z. The ability to variably position the sonotrode contact surfaces may also be used to quickly perform adaptations on the part of the plasticization assembly when switching the product geometry to be produced.
The use of so-called co-traveling stamping-motion sonotrodes and so-called rolling sonotrodes is also possible. However, static sonotrodes with a dragging contact to one of the profile parts are preferably used in the method in accordance with the invention (dragging sonotrode).
Performing a continuous through-feed method avoids, in particular, the problem of offset points, which arise, e.g., in a cycled advancing method with cyclically moved sonotrodes or cyclically moved presses.
The sonotrode(s) is/are placed in the required position relative to the profile parts either with a defined pressing force (force control) with a certain contour or a certain location (“travel to end stop”, path control).
The sonotrode is thereby in contact with the components to be joined substantially perpendicularly in relation to the cross section so that the energy (ultrasonic oscillations) can be ideally introduced and mechanical forces that arise can be directly dissipated. It may be the case that, due to geometric restrictions on the part of the profile parts, a perpendicular placement of the sonotrode(s) is not possible, and in this case angled sonotrodes or sonotrodes with angled contact surfaces or with contoured contact surfaces may be used, wherein the contact surface of the sonotrode in cross section perpendicular to the transport direction should have a contour that matches the profile surface.
The sonotrodes, specifically the dragging sonotrodes, are preferably made of metallic materials that are resistant to frictional wear (e.g., hard or hardened steel, titanium, and corresponding hard alloys) or are equipped with coatings on the contact surface that are resistant to frictional wear. Such wear-resistant coatings may be, among other things, typical hard coatings from PVD/CVD (physical/chemical vapor deposition) processes or hardened wet-chemical coatings (e.g. ceramic coatings). In tool making, such methods and coatings are sufficiently known and available. Carbon-based coatings, e.g., so-called diamond-like carbon coatings, as well as oxide, nitride, or carbide coatings are particularly preferable.
The sonotrodes may be operated continuously or in short intervals, for example in fractions of a second, pulsed, or in longer cycles of a few seconds or minutes. The sonotrodes are preferably, as a rule, continuously in operation during the passage of the profile parts. As a result of the high input of energy, measures must be taken to dissipate excess heat, e.g., cooling the sonotrodes with air, water, or other media, as well as equipping surfaces with coating with a high emissivity to improve the heat dissipation.
The plasticization characteristics of the second plastics material can be controlled by different parameters, among other things the design of the profile geometries of the first profile part (wall thicknesses, profile shapes, design of the melting region) and the associated receiving structure, the lowering level, the sonication depth and other things. The selection of the materials for the profile region of the first profile part (rigidity, E-modulus, melting temperature, softening temperature, glass transition temperature, material densities, loss factors for the respectively introduced energy etc.) and the joining parameters (advance speed, lowering speed, energy input, frequency/amplitude of the ultrasonic sonotrode, preheating the first profile part and/or the second profile part) are important.
The plasticization characteristics of the second plastics material can also be influenced by the second profile part or by the material of the second profile part. For example, easily co-vibrating or resilient profile geometries of the second profile part are disadvantageous for the plasticization characteristics. These disadvantages can be eliminated by constructive features (increasing the wall thicknesses in the region of the receiving structure, supporting the receiving structure by means of force-dissipating webs etc.).
After the plasticization section, a holding section is arranged in which the possibly still hot plasticized mass of the second plastics material of the melting region can cool and solidify in a controlled manner after deformation. In this region of the holding section, the profile parts are held in the desired relative position to one another and optionally are conveyed further in the longitudinal direction. It is also possible to convey the profiles transversely. If necessary, mechanical pressure may thereby also be introduced, for example by means of pressing rollers, cylinders, dragging pressing rails, holding matrices, or chain- or band-driven pressing elements (band withdrawal). The cooling typically happens quickly due to the dissipation of heat by the material of the first and in particular the second profile part, if the latter is produced from a metallic material. If required, excess heat can also be dissipated by cooling, for example by means of air, water, oil, or other media.
After passing through the joining region, the positively engaging connection between the profile parts is formed and the composite profile is transported further into an outlet region where a removal of the profile can take place or, optionally, successive further processing steps (bundling, foiling, packaging, signing, cleaning, pretreating, coating etc.) can take place.
It is also possible to place the sonotrode in contact with the second profile part in order to input energy through the material of the second profile part (for example metal) into the material (second plastics material) of the profile region of the first profile part in such a way that the plasticization of the second plastics material is possible and the formation of a positive engagement is achieved. This is particularly preferable if the material of the second profile part has a higher rigidity than the material of the first profile part, e.g., a rigidity that is twice as high (measurable as E-modulus, e.g., with aluminum or stainless steel) and/or the ultrasound can be guided as rectilinearly as possible from the region of the sound introduction to the receiving structure and/or these sound-conducting profile structure of the second profile part are designed to have thick walls, for example with wall thicknesses of about 2 mm or more.
According to the method in accordance with the invention, the positive engagement(s) is/are preferably produced with a shear strength in the longitudinal direction of the composite profile of about 2 N/mm or more, particularly preferably about 5 N/mm or more. More specifically, the shear strength is at least 2 N/mm, especially at least 5 N/mm. The shear strength of composite profiles (metal profiles with a thermal break) can be determined according to DIN EN 14024:2004.
The method in accordance with the invention makes it possible, in particular in any combination, that the first and/or the second profile part and/or the third profile part are provided as endless material or as bar-type goods.
Further, according to the method in accordance with the invention, the second profile part and/or the third profile part are provided with a receiving structure in the form of a recess which, seen in cross section perpendicular to the longitudinal direction of the composite profile, has an undercut at least in sections.
In addition, according to the method in accordance with the invention, the cross section of the receiving structure of the second profile part and/or the third profile part, seen perpendicular to the longitudinal direction of the composite profile, may vary along the longitudinal direction in its width and/or depth, for example as a result of compression moulding of regions of the second/third profile parts.
The creation of particular cross sectional geometries of the second and/or third profile parts may take place in the process sequence, i.e., before the joining process or in a separate process performed beforehand.
Furthermore, according to the method in accordance with the invention, before the plasticization of the profile region or the profile regions, the first profile part and the second and optionally the third profile part can be positioned by means of a first guidance apparatus in a predetermined, optionally variable relative position to one another and be guided in the longitudinal direction of the composite profile.
In a further variant of the method in accordance with the invention, after the plasticization and deformation of the profile region or the profile regions, the first profile part and the second and optionally the third profile part can be positioned by means of a second guiding device in a predetermined, optionally variable relative position to one another, and be guided in the longitudinal direction in order to, for example, reach, maintain, or optionally correct a predetermined lowering level.
Also, according to the method in accordance with the invention, after the plasticization and deformation of the profile region or the profile regions and upon passing through an optional second guidance apparatus following the plasticization and deformation of the profile region(s), the first profile part and the second and optionally the third profile part can be pressed against one another with a predetermined force and can then be held in the same or in a further predetermined relative position until the plasticized second plastics material has solidified.
According to a further variant of the method in accordance with the invention, after the plasticization and deformation of the profile region or the profile regions and upon passing through an optional second guidance apparatus following the plasticization and deformation of the profile region(s), the first profile part and the second and optionally the third profile part can be pressed against one another in a predetermined relative position and can then be held in the same or in a further predetermined relative position until the plasticized second plastics material has solidified.
According to the method in accordance with the invention, the profile region or the profile regions of the first profile part is/are preferably configured as a projection or as projections, which extends/extend away from a surface of the first profile part by about 10 mm or less, preferably about 6 mm or less. More specifically, the projection or projections extend away from a surface of the first profile part by at most 10 mm, preferably at most 6 mm. A sufficiently large mass of the second plastics material can thus be made available in order to be able to produce positive engagements for the absorption of large forces (tensile, shear, bending etc.). Shorter projections are also preferred, because they can be better sonicated and thus the plasticization is easier to achieve.
In the method in accordance with the invention, the first profile part and the second profile part, optionally together with the third profile part, are preferably guided toward one another at an acute angle with respect to the longitudinal direction of the composite profile, wherein the guidance extends at an acute angle at least over partial regions of the zone of plasticization and deformation and optionally in the first and/or second guidance apparatus.
Further, in the method in accordance with the invention, the plasticization is performed by means of sonication, preferably in the so-called near-field method, wherein a sonotrode thereby has a direct contact to one of the profile parts. A distance of the contact surface of the sonotrode from the respective other profile part is thereby preferably about 10 mm or less, further preferably about 6 mm or less. More specifically, the distance of the contact surface of the sonotrode from the respective other profile part is at most 10 mm, preferably at most 6 mm.
In preferred methods in accordance with the invention, the zone for the plasticization, measured in the longitudinal direction of the composite profile, has a length of about 5 cm to about 100 cm, preferably a length of about 5 cm to about 50 cm, wherein optionally an ultrasound unit with one or more sonotrodes is used for the plasticization.
It is further preferable in the method in accordance with the invention that the contact surface(s) of the sonotrode(s) in the zone of plasticization and deformation, in relation to the longitudinal direction of the profile part(s) in contact with the sonotrode(s), is/are at a distance from a surface of the other profile part(s) of the composite profile, said distance decreasing along the longitudinal direction of the composite profile seen in the passage direction (lowering level).
The contact surface(s) is/are thereby arranged in an angular position or in different angular positions, wherein the angular positions may vary continuously and/or in steps.
In the method in accordance with the invention, the sonotrode to be used in the zone of plasticization and deformation is preferably selected as a static sonotrode, which is configured, in particular, as a dragging sonotrode. That means that a profile part is dragged along the contact surface of the stationary or standing sonotrode, while the sonotrode oscillates at an ultrasonic frequency.
In the method in accordance with the invention, the produced composite profile, seen in the longitudinal direction of the composite profile, is conveyed at a speed of about 3 m/min or more, in particular about 10 m/min or more. More specifically, the conveying speed is at least 3 m/min, preferably at least 10 m/min.
In the method in accordance with the invention, the dwell time of the profile parts in the zone of plasticization and deformation is preferably about 0.1 sec to about 10 sec, further preferably about 0.2 sec to about 5 sec.
In the method in accordance with the invention, the sonotrode is preferably operated continuously.
The present invention further relates to a composite profile, produced according to the method in accordance with the invention.
In the composite profile in accordance with the invention, the first profile part has, in particular, one or more functional elements. By means of the functional elements, the composite profiles can be easily adapted to a multitude of requirements and tasks.
The composite profile in accordance with the invention will often comprise a second profile part, which has a visible side surface on which the receiving structure is formed.
The first profile part, after the formation of the positive engagement, may then be arranged with a surface region flush with the visible side surface.
In preferred composite profiles in accordance with the invention, the first profile part, after the formation of the positive engagement, substantially completely covers the region of the second profile part at which the receiving structure is formed.
Particularly appealing visible surfaces of composite profiles can thereby be achieved. In comparison to conventional roll-in profiles, in preferred embodiments, there are hardly any or no direct indications of the connecting structure/geometry hidden beneath when viewed from the outside.
Preferred composite profiles in accordance with the invention have a visible side surface, which is formed by the visible side surface of the second profile part, a surface region of the first profile part arranged flush with the visible side surface of the second profile part, and optionally a visible side surface of a third profile part, wherein the visible side surface of the third profile part is preferably arranged flush with the surface region of the first profile part.
The profile parts used, assuming they are provided as plastic profiles, are preferably produced in an extrusion process. In addition, pressed, calendered, pultruded, or other strand-shaped profile parts produced in a different manner may be used. Fabric reinforced or endless fiber reinforced thermoplastic composite materials, so-called prepregs, organic tapes, organic sheets, or in general composites in long sheets or strips are particularly preferable. These materials may be different in composition and geometry or can be easily formed to desired geometries of the respective profile part (“thermoforming”). Further components may be subsequently attached or moulded on as required.
The profile parts used in the method in accordance with the invention may, unlike typical roll-in profiles from the prior art, have other forms, which in particular have better mechanical and also better optical properties. The composite profiles formed may also have new cross sectional geometries that were previously inaccessible.
While linear composite profiles are desired or required in many areas of application, in some applications, a design of bent or twisted composite profile geometries may be desired or required. An adaptation of the method in accordance with the invention makes it possible to set appropriate bend radii (to produce composite profiles bent in the longitudinal direction or, in the extreme case, shaped into rings or spirals), or twist angles or torsion angles (to produce composite profiles twisted in the longitudinal direction in the shape of a screw).
The composite profiles are preferably designed such that the lowering level is low, for example smaller than about 10 mm, preferably smaller than about 6 mm, further preferably smaller than about 3 mm.
Likewise, in composite profiles in accordance with the invention, the profile parts are preferably constructed such that the distance between the potential contact surface of the sonotrode with the first profile part and the remote end of the associated profile region (melting region) of the first profile part is small (small sonication depth), namely preferably smaller than about 20 mm, further preferably smaller than about 10 mm, most preferably smaller than about 6 mm.
The first profile part, in particular in the form of an insulating profile, may itself be configured in different forms and have, in addition to the profile regions made of the second plastics material (melting regions), a multitude of further functional zones or functional elements, which are known from the prior art for the respective target application, for example flags and/or hollow chambers for reducing convection, screw channels, grooves, hooks, for example for accommodating seals or metallic elements, stops in the form of noses, arrows, centering and assembly aids, special projections for accommodating transverse tensile forces and so on.
The profile regions of the first profile part (melting regions) may also be configured in different forms. Symmetrical or asymmetrical cross sections with at least one taper, for example pointed, rounded forms with one or more points or terminal rounded portions, are preferred. Blunt melting regions may also be used. It is also possible to introduce a taper, for example in the form of a waisting, into a melting region. The taper hereby has the purpose of concentrating the ultrasonic energy and predetermining a region in which the plasticization operation begins, wherein this region is then located within the melting element and thereby initially has no contact with the receiving structure or the material of the receiving structure (until the deformation).
Associated with a melting region of the first profile part, a respective receiving structure is provided on the part of the second profile parts. Said receiving structure accommodates the melting region of the first profile part and provides a volume for the plasticized second plastics material of the melting region. The receiving structure is also configured in such a way that a connection by positive engagement becomes possible, for example by means of undercut regions.
The receiving structure is preferably configured as a continuous groove with an undercut, such that a sort of receiving volume extending in the longitudinal direction arises in the cross section perpendicular to the longitudinal direction of the composite profile. This groove may be both symmetrical and asymmetrical in cross section perpendicular to the longitudinal direction and, for example, taper or widen in cross section. This groove may also contain an element tapering toward the groove opening, for example in the form of a triangular cross-section, which element can then function as a so-called energy director in the ultrasonic welding process and both concentrates the ultrasonic energy in the tip and simultaneously diverts the plasticized mass along the flank of the triangle.
The groove is configured with respect to its cross sectional geometry in such a way that it can completely accommodate the resulting melting volume of the profile region (melting element) of the first profile part. The volume provided by the groove may optionally be formed somewhat larger than the resulting melting volume. A buffer may thereby be advantageous to compensate for a possible deviation of the melting volume, which deviations may result from geometric variations, fluctuations in the plasticization process etc.
The groove itself may also be configured such that the profile region (melting region) centers itself.
In a further variant of the method in accordance with the invention, a composite profile may be produced with very good profile statics from two profiles of the type of the first profile part and two profiles of the type of the second profile part by the two first profile parts, in addition to the connection by positive engagement of the first and second profile parts, being joined by substance-to-substance bond (e.g. adhesive bonding or welding). This process may also be combined in a direct process sequence with the production of the positive engagement or form fit.
An adhesive, for example a melting adhesive or a melting wire with melting adhesive content, may preferably be applied in the receiving structure and/or on or at the melting region.
A separate adhesive does not necessarily have to be introduced in the region of the receiving structure, but rather may also be applied in the adjacent regions, wherein the adhesive should have contact with the first and the second profile part. Adhesives of that kind may then optionally be thermally activated only in a later process step (e.g., by means of powder paint baking).
Composite profiles produced in accordance with the invention thereby have a multitude of advantages:
Composite profiles in accordance with the invention can be produced without knurling an aluminum profile. Alternative possibilities for increasing the strength and in particular the shear strength can be achieved—if necessary—by optimizing the geometry of the receiving structure, and additional use of (melting) adhesives, the use of friction-increasing means (sharp-edged particles, e.g., sand, corundum etc.) in the positive engagement region.
Composite profiles in accordance with the invention achieve a better heat insulation without having to vary the main dimensions, in particular the installation depth Lb of the composite profile. An increase of the so-called insulation depth Li improves the so-called Uf values. Composite profiles in accordance with the invention with a cross section of smaller dimensions can be achieved while maintaining the same Uf values.
The freedom of design in composite profiles in accordance with the invention is significantly increased, and in particular composite profiles with smooth visible surfaces can be achieved. The striking and unpleasant positioning of the knurling marks in visible regions, as is required in some cases in the roll-in method, can be avoided.
Common functional elements like, for example, flags, hollow chambers, noses, hooks, stops, grooves etc., can easily be integrated into the structure of the composite profiles in accordance with the invention. The combinability with known production steps, e.g., foiling with metallized or metallic foils, the attachment of foams, e.g., adhesively bonded plastic foams (PE, PP, PET, PS, PA, PU etc.) or reactive insulating foams (PUR), cover films or anti-scratch films and so on, is also possible.
Relevant characteristic data of the bond can be improved: The shear strength can be increased by means of the good positive engagement. The transverse tensile strength of the composite profiles can be increased, because, for example, smaller or no chamfer angles have to be constructively integrated into the first profile parts designed as insulating profiles.
The torsional rigidity can be improved because first profile parts, in the form of insulating profiles, abutting on the outside against the second profile parts increase the geometrical moment of inertia.
Undercuts in metal profiles that are used as a second profile can be of a more solid configuration because a roll-in hammer that has to be deformable in a cold state is not required. More solid connections can thus be achieved.
The function of the formation of a positive engagement can be decoupled from further mechanical functions to be considered, for example the absorption of transverse tensile forces. As a result, the different functions of the composite profile can be optimized more simply and at least partially independently of one another.
A simplified production of the aluminum extruded profiles is conceivable, because simpler cross sections are possible (relatively thin-walled and complicated structures in the region of the roll-in geometry (hammer and anvil)).
The process of forming the positive engagement or form fit is thereby better controllable and the proportion of rejects is reduced.
The positive engagement can be produced with high production speeds.
A warp-free connection of the profiles is possible because there is no cold deformation of the metal.
The tightness of the connection zone of the first and second profile part is improved and thus an increase in the driving rain water tightness can be achieved.
Because the insulating profiles no longer necessarily have to be inserted in the longitudinal direction into the metal profiles, but instead can be placed like a lid, the accessibility to a cavity in the composite profile is simple and is possible over the entire profile length. As a result, for example additional product components can be more easily introduced into the cavity, for example in order to improve fire protection, sound insulation, the thermal insulation properties, or the profile statics. This includes, among other things, the insertion of foam strips, insulating material, reinforcing struts or profiles, clips made of metals or plastics materials, the introduction of reactive foam masses etc.
By means of the welding process, not only can the plastic profile (first profile part) be fixedly connected to the aluminum profile (second profile part), but also optionally a plurality of plastic profiles with one another. Thus, transversely braced profiles with improved statics of the composite profile can be produced in the same manufacturing process.
The use of flat, tape-shaped composite materials like e.g. so-called organic tapes or organic sheets in the form of strips is possible as an alternative starting material for plastic profiles (first profile parts). This opens the way to more effective composite profiles. The necessary profile regions can be simply applied to these flat materials, for example retroactively by corresponding shaping or by moulding (injection molding, welding etc.) functional zones made of compatible plastics materials.
The plastic profiles (first profile parts) in composite profiles in accordance with the invention can be larger (compared with traditional roll-in composite profiles) with the size of the cross section of the composite profile remaining the same, and thus a greater insulation depth can be achieved. Likewise, the composite profiles in accordance with the invention can be configured with a smaller cross section than in corresponding roll-in composite profiles with the same insulation depth. More intricate and/or better insulating window/door/facade systems can thus be built.
Composite profiles produced in accordance with the invention can be easily recognized by a test sample being taken from a longer composite profile and further relevant features can be confirmed. By means of an optical or, better, a microscopic analysis of suitable cuts, a person skilled in the art can trace the emergence of the positively engaging connection back to the plasticization of the plastics material. Cross sections can be made either with a cleanly performed saw cut or, better, as a micrograph of test samples embedded in resin. A person skilled in the art for joining technology will be able to associate further characteristic features with the method.
These and further advantages of the invention will be explained in more detail in the following in the context with the drawings.
The composite profile 10 has two plastic profiles 12, 14, which are arranged between two metal profiles 16, 18 and hold same at a predetermined distance Li (insulation depth). The width (installation depth) of the composite profile 10 is designated in
The two plastic profiles 12, 14 are configured as hollow chamber profiles and have on their opposite sides so-called roll-in heads 20, 21, which are introduced into corresponding complementary roll-in grooves 22, 23 of the metal profiles 16, 18.
The metal profiles 16, 18 have projections 24, 25, and 26 angled toward one another in pairs, which form a receptacle for further components, for example sealing elements or locking bars.
In the present embodiment, the first profile part 30 in its totality, i.e., its base body and the profile regions 34 moulded thereon, are produced from one plastics material, i.e, in this embodiment the first and second plastics materials are identical and are produced in one single extrusion process.
The metal profiles 42, 44 are configured as hollow profiles and have on one side receiving structures in the form of receiving grooves 46, 48, which have a T-shaped cross section seen perpendicular to the longitudinal direction Z of the profiles, said cross section providing a volume in which the plastics material of the profile regions 34 can be accommodated upon the formation of a positive engagement in accordance with the invention.
In
The four components of the composite profile 40 to be produced can, as a whole as depicted in
Compared to the embodiment of
In the present embodiment, too, the first profile part 60 in its totality, i.e., its base body 62 and the profile regions 64 moulded thereon, are produced from one plastics material, i.e., in this embodiment the first and second plastics materials are identical.
In
The four components of the composite profile 70 to be produced can be fed as a whole, as shown in
In comparison with the embodiment of
The first profile part 82 is configured as a hollow chamber profile, wherein the profile geometry is based on a web-shaped base body 88, onto which a hollow chamber structure 92 with four hollow chambers is moulded on a first surface 90. On both sides of the hollow chamber structure 92, a first and a second profile region 94, 96 extend substantially perpendicularly away from the surface 90 of the base body 88. The two profile regions 94, 96 have at their free ends a substantially triangular cross section.
The second profile parts 84, 86 are arranged on both sides of the first profile part 82 and have on their regions facing toward the first profile part a receiving structure in the form of grooves 98, 99 that are T-shaped in cross section. In the illustration in
In a next step, the first profile part 82 is, preferably simultaneously, placed on the two second profile parts 84, 86, such that the two profile regions 94, 96 of the first profile part loosely engage in the grooves 98, 99 of the second profile parts 84, 86 and form a physical contact, as is shown in
In a subsequent step, a sonotrode is placed with its contact surfaces 102, 104 on the surface 100, opposite the surface 90, of the base body 88 of the first profile part 82, as shown in
The lowering level hS that arises in the method in accordance with the invention in the production of the composite profile in accordance with the invention can be seen in the comparison of the positioning of the first profile part 82 with the second profile parts 84, 86 in
In the present embodiment, the first profile part 82 in its totality, i.e., its base body 88 and the profile regions 92, 94, 96 moulded thereon, are produced from the same plastics material, i.e., in this embodiment the first and second plastics materials are identical. The targeted plasticization of the profile regions 94, 96 when acted upon by the ultrasound of the sonotrode results from the form of said profile regions 94, 96. Other portions of the first profile part 82, in particular the base body 88 and the hollow chamber structure 92, retain their original form during the plasticization process, even if they are produced from the identical plastics material as the profile region.
Alternatively, the profile regions 94, 96 may also be produced from a second plastics material, for example extruded onto, coextruded with, welded onto, or adhesively bonded to the base body 88. With this approach, the first and the second plastics material can each be selected substantially independently of one another and optimized for the respective purpose.
The second profile parts 84, 86 have projections 112, 113 angled toward one another in pairs, said projections serving to receive further components, for example sealing lips. The first profile parts 82, 82′ also have projections 116, 118 and 116′, 118′, respectively, angled toward one another in pairs, which also can accommodate further components like, e.g., sealing elements or locking bars.
The cross sectional geometry thus corresponds substantially to the cross sectional geometry of the conventional composite profile 10 from
This results in a significantly (about +33%) higher insulation depth Li with the same installation depth Lb, wherein the base structure of the two metal components (second profile parts) 84, 86 can be simplified and otherwise remains unchanged. In particular the configuration of the grooves 98, 99 and their surroundings in which, for one, the first profile part 82 can take on a functional element and, for another, the metal component can be designed more simply in the region of the respective groove 98, 99, because a deformability or shapeability of the metal component in the region of the grooves 98, 99 is not required. Moreover, a better appearance on the respective visible sides of the composite profile can be achieved, because, in particular, knurling marks, as shown in the region of the roll-in connections in
It can be seen in the embodiment of
A further embodiment of a composite profile 150 in accordance with the invention can be seen in
Like in the case of the composite profile 80 in
The first profile parts 152, 154 are first profile parts that are produced from a base body 168 and 170, respectively, from which in each case projections 172, 173, 174 and 176, 177, 178, respectively, project perpendicularly (“flags”) at regular intervals in the longitudinal direction of the first profile parts 152, 154, which projections are formed on the base body 168 and 170, respectively, and, as shown in
This base geometry visible in
As can be seen in
A further possible variation is depicted in
The first profile part 222 is based on the base structure of a first profile part 200, as depicted in
A further particularity is shown in
The production in accordance with the invention of a composite profile 250 in accordance with the invention is depicted in multiple steps in
In a first method step, the two first profile parts 200, 252 placed on the second profile parts 156, 158—as already explained in detail in the preceding embodiments—are connected by positive engagement or form fit by plasticizing the profile regions 204, 206 and 258, 260, respectively, thus resulting in a structure as is depicted in
Furthermore, the flag-like projections 262, 264, 266 may be used to produce a positively engaging connection of the first profile part 252 to the other first profile part 200, and this, too, may take place as part of an ultrasonic welding, as is shown schematically in
A one-piece structure made of the two first profile parts 200 and 252 is created after the ultrasonic welding, as is shown in
Depicted in
On this basis, depicted in
A first alternative of this is shown in
A further possibility for the configuration of the meltable profile region is shown in
Depicted in
The first profile part 300 is distinguished from the other variants described so far by additional functional elements 310, 312 being arranged (here moulded on in one piece) as assembly aids on the surface 304 from which the profile regions 306, 308 already project as meltable projections, said functional elements ending with a hook-shaped projection.
In a first step of the method in accordance with the invention for producing the composite profiles in accordance with the invention, the two first profile parts 300, 300′ are brought together with the two second profile parts 156, 158, now thus obtaining a structure that can be easily handled due to the assembly aids in the form of the hook-shaped projections 310, 312 and 310′, 312′, respectively, thereby significantly simplifying the process of producing a positively engaging connection during the ultrasonic welding. The projections 310, 312 and 310′, 312′ also aid in the exact positioning and centering of the joining partners.
The completed structure of the composite profile 320 connected by positive engagement is depicted in
The following
Shown in
In the embodiment for a receiving structure of
Shown in
In a similar form, this also applies to
The above special embodiments for receiving structures show that a large variation is possible with the groove-shaped receiving structures, which, for one, can take into account a possibly limited amount of space in the cross section of the second profile part 156 and/or can achieve further improvements in the production of the positive engagement.
Further variants for receiving regions of second profile parts are shown in
In
An alternative is shown in
A further variant of a groove-shaped receiving structure 380 is shown in
Due to the specially designed structure, in particular on the part of the surface 384, when a second plastics material penetrates in a positively engaging manner upon the formation of a positive engagement by a melting profile region of a first profile part, a positive engagement is achieved not only by way of the actual receiving structure 380, but also a particularly high shear strength is achieved by second plastics material also possibly being introduced into the bulges or notches of the knurled structure 386 on the part of the surface 384.
In particular, the downward facing tips 388 (cf.
The apparatus 400 has a first guidance zone 402 (guidance elements not shown) in which the initially separately produced profile parts of a composite profile to be connected to one another, using the example of the composite profile 80 in
Following the welding zone 404 in the conveying direction F is a holding zone 406, which holds the profile parts 82, 84, 86, which were brought together and connected by positive engagement in the welding zone 404, as a finished composite profile 80 in their relative position to one another so that the plasticized and deformed second plastics material 106, 108 can cool and thus the produced positive engagement can solidify.
A sonotrode 410 arranged in the welding zone 404 is, in
Due to the shown geometric arrangement of the sonotrode 410 in relation to the support 416 (counter bearing) and the conveying direction F, the material of a profile region 94, 96 can be continuously plasticized and promptly pressed in the plasticized state such it that can enter into the receiving structures (grooves 98, 99) of the second profile parts 84, 86, fill same, and thus form a positive engagement or form fit 106, 108 between the first profile part 82 and the second profile parts 84, 86.
Here, a sonotrode arrangement 454 with two sonotrodes 466, 458 is used in a welding zone 452, which sonotrodes are controllable and operable independently of one another, wherein the two sonotrodes 456, 458 of the sonotrode arrangement 494 are aligned with their contact surfaces at different angles α1 and α2 to the transport plane of the composite profile 80. The angle α1 is selected smaller than the angle α2. An average contact angle α arises over the entire course of the sonotrode contact. Here, a successively increasing introduction of force into the composite profile 80 and its profile parts take place, which, due to the use of two sonotrodes 474, 476, can be more easily adapted to the material properties and the geometry of the second plastics material of the profile region(s) 94, 96, as well as the feed-through speed of the composite profile 80.
An alternative design of a welding zone 472 as part of an apparatus 470 is depicted in
A holding zone with a guidance apparatus (not shown) is provided following each welding zone 452 and 472, said holding zone holding the elements of the composite profile 80, connected to one another by positive engagement, in the desired cross sectional geometry, such that the formed positive engagement can cool and finally a handleable composite profile 80 with the desired geometry is obtained.
A further variant of an apparatus 500 for producing, in accordance with the invention, a composite profile 80 in accordance with the invention is schematically shown in
The welding zone 502 is equipped with two sonotrodes 504, 506, which are arranged opposite one another above and below the composite profile 80. The sonotrodes 504, 506 each form a counter bearing or a support for one another. Both sonotrodes 504, 506 are arranged with their contact surfaces 508, 510 at an angle α to the conveying direction F. The profile parts of the composite profile can thereby be brought together in their positions in the completed composite profile substantially in parallel to the energy input and the plasticization of the second plastics material of the meltable profile regions of the first profile parts.
The welding zone 502 is followed in the conveying direction F by a holding zone 512 in which the plasticized and deformed profile regions can cool and harden while preserving the positive engagement with the second profile parts.
With this apparatus variant, both first profile parts can be connected by positive engagement to both second profile parts in one step and simultaneously.
In a further embodiment of an apparatus 550 for carrying out the method in accordance with the invention according to
Provided opposite the sonotrode 560 is a support 564, which supports the composite profile or its profile parts when passing through the sonotrode 560.
Following that, the second welding zone 554 is provided with a second sonotrode 566, which is arranged below the composite profile 80 and has a contact surface 568 that is also oriented inclined at an angle α to the conveying direction F.
Arranged opposite the sonotrode 566 is a guide block 570, which, for one, absorbs the pressure exerted by the sonotrode 566 and, for another, together with a further support 572 forms a holding apparatus that supports and guides the composite profile 80 in the final joined and positively engaged state during the cooling and solidifying of the positive engagement elements formed in the welding zones.
The composite profile 80 or its constituent parts 82, 82′, 84, 86 are conveyed in the conveying direction F to a holding apparatus that here is configured schematically with a roller 592, which has on its outer periphery two annular projections 594, 596 spaced in parallel to one another that, like the two sonotrodes 584, 586, engage in a matching manner into the surface structure of the composite profile 82 and hold the plasticized profile regions 94, 96 in form so that a positive engagement 106, 108 with the first profile part 82 can form in the receiving grooves 98, 99 of the second profile parts 84, 86. A plurality of rollers 592 may also be arranged in series.
The supports or counter bearings discussed in the preceding
A feed-through speed or a withdrawal speed of the finished insulating profile 80 is typically within the range of about 3 m/min or more, whereby significantly higher values are also realizable, for example about 10 m/min or more.
The dwell times of the profile parts in the welding zone that are predetermined by the aforementioned withdrawal speeds are heavily dependent on the material and the geometry and typically amount to about 0.2 sec to about 5 sec. If a higher energy input should be necessary, then one can work with somewhat lower withdrawal speeds (thus corresponding to a longer dwell time) so that, upon passing through the welding zone, a higher input of energy (taken with reference to the unit of length of the positive engagement) can take place. In general, with significantly higher withdrawal speeds, an extension of the welding zone becomes necessary, for example by adding further sonotrodes, something that typically can easily be realized, however, in the method in accordance with the invention.
The duration of the compression process, i.e., the period in which the composite profile connected by positive engagement is guided and stabilized by a holding apparatus, is conceived on the basis of the time that is required in order to let the plastics material solidify and to make the composite profile able to be handled as such. Here, typically durations of about 0.2 sec to a few seconds are sufficient, because the plasticization is limited and the amount of heat that has to be dissipated is relatively small and, in addition, in the case that metal profile parts are used as second profile parts, a good heat dissipation is ensured.
In
In
The first profile part 602 has a first profile region 610, which, as already described in the context of various embodiments, can be plasticized and inserted into a groove-shaped recess 612 on the part of the second profile 608 and be connected by positive engagement.
Provided on the opposite side of the first profile part 602 is a further profile region 614, the second plastics material of which is also plasticized in accordance with the invention and is brought into positive engagement with a receiving structure 616 on the part of the second profile part 606. The receiving structure 616 differs from the receiving structure of the groove 612 in that there are separate structures for absorbing transverse tensile forces and for forming the positive engagement and, for one, only one set-back portion 618 without undercuts is provided, into which the profile region 614 can partially engage. For another, in each case structured surface regions 620, 622 adjacent to the set-back portion 618 are provided on the surface of the profile part 606, in which surface regions a multitude of undercuts are provided, such that the material plasticized on the part of the profile region 614 is able to penetrate into the structures of the surfaces region 620, 622 in order to achieve a positive engagement. The structured regions 620, 622 serve primarily to fix the first profile part 602 to the second profile part 606, while the remaining projection from the profile region 614 that engages into the set-back portion 618 is designed to absorb tensile forces that may arise in the width direction of the first profile part 602.
There is a similar functionalization on the part of the further first profile part 604, in which a profile region 624 is provided that is brought into contact with a receiving structure 626 on the part of the second profile part 608 and ultimately forms a positively engaging connection therewith. In addition hereto, provided on the same side of the first profile part 604 is a strip-shaped projection 628, which, when joining the first profile part 604 to the second profile part 608, engages into a set-back portion 630 in order to absorb primarily transverse tensile forces.
On the other side of the first profile part 604 is a profile region 632, which can be brought into contact with a receiving structure with a multitude of undercuts 634 on the part of the second profile part 606 and thereby is shaped into a positively engaging connection as part of the plasticization and the bringing together of the two profile parts.
The receiving structure with the multitude of undercuts, as it is used in the receiving structures 620, 622, 626, and 634, is depicted in an enlarged view again in cross section in
Receiving structures of that kind can be introduced, e.g., by means of an extrusion process even into aluminum profiles, or in other forms by means of surface finishing steps, for example by means of mechanical, chemical/physical surface finishing.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2020 109 830.8 | Apr 2020 | DE | national |
