Patent Application
20210301585
This patent application claims priority to German Patent Application No 10 2020 108 568.0, filed Mar. 27, 2020, which is incorporated herein by reference in its entirety.
The present disclosure relates to a profile, in particular an extrusion profile, such as a monoextrusion or co-extrusion profile, for a window and/or door part, in particular a window and/or door frame part or a window and/or door leaf part, and to a method for producing such a profile.
In the prior art, it is known to increase the attractiveness of door and/or window frames by laminating the visible outer or inner sides of the frames with a plastic film, which is intended to imitate, for example, a wooden appearance, a concrete-like appearance or the like. The use of plastic is increasingly frowned upon in most industries these days. There is therefore a fundamental demand for more environmentally friendly products. At the same time, there is an increasing demand for customized, individualized door and/or window frame parts.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the embodiments of the present disclosure and, together with the description, further serve to explain the principles of the embodiments and to enable a person skilled in the pertinent art to make and use the embodiments.
The exemplary embodiments of the present disclosure will be described with reference to the accompanying drawings. Elements, features and components that are identical, functionally identical and have the same effect are—insofar as is not stated otherwise—respectively provided with the same reference character.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. However, it will be apparent to those skilled in the art that the embodiments, including structures, systems, and methods, may be practiced without these specific details. The description and representation herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, and circuitry have not been described in detail to avoid unnecessarily obscuring embodiments of the disclosure. The connections shown in the figures between functional units or other elements can also be implemented as indirect connections, wherein a connection can be wireless or wired. Functional units can be implemented as hardware, software or a combination of hardware and software.
An object of the present disclosure to overcome the disadvantages of the prior art, in particular to simplify the production of individualized and/or environmentally friendly profiles for window and/or door frame parts or window and/or door leaf parts.
According to this, a profile is provided for a window and/or door part, for example a door and/or window frame part or a door and/or window leaf part. The profile may be, for example, a profile made in particular of plastic, such as PVC, in particular an extrusion profile, for example a monoextrusion profile or a co-extrusion profile. Generic profiles can be produced, for example, by pultrusion or by extrusion. In the context of the present disclosure, the terms extrusion profile, monoextrusion profile or co-extrusion profile are to be understood as meaning that the corresponding profile is produced by extrusion, monoextrusion or co-extrusion, respectively. The extrusion process may be monoextrusion or co-extrusion.
The profile according to an exemplary embodiment of the disclosure can, for example, at least in sections form a door and/or window part, such as a bar, such as a vertical bar or a horizontal bar, either of a fixed door and/or window frame part or of a movable, in particular displaceable and/or pivotable, door and/or window leaf part. In the case where the profile is formed as a plastic extrusion profile, the profile first comprises an extrusion semi-finished product produced by extrusion, which has a substantially identical cross-section along the extrusion direction as well as a substantially identical outer dimension.
According to an exemplary embodiment the disclosure, the profile comprises a fiber layer laminated by means of an adhesive at least partially to an outer side of the profile, in particular to a profile web forming an outer side of the profile and/or facing outwardly. In the context of the present disclosure, the fibers forming the fiber layer may be a linear, elongated structure with a cross-sectional shape that is round, angular, or the like, and is thin and flexible in relation to its length. Generally, fibers are characterized by the fact that they cannot absorb compressive forces in the longitudinal direction, but only tensile forces. Laminating is generally understood to mean the connection of a plurality of layers by means of a laminating agent comprising at least one adhesive according to the present disclosure. Lamination of the particularly thin and/or flexible fiber ply has proven to be particularly advantageous with respect to production, since, on the one hand, the fiber plies can be stocked in a simple and space-saving manner, for example by winding them onto a stock roll, and, on the other hand, the lamination process is surprisingly well suited not only for plastic films but also for fiber plies. The flexible fiber layer can be elastically stretched or bent to a certain extent, in particular in such a way that it can be easily applied to non-planar profile surfaces and adapted in shape in this respect. According to the present disclosure, a fiber layer can be understood as flexible if it can be wound or rolled onto a roll, in particular for stocking purposes. The thin fiber layers can be adapted and laminated to even irregular profile outer surfaces in a particularly form-fitting and true-to-shape manner, so that a uniform, durable and accurately fitting lamination of the corresponding profile outer surface can be ensured. Another advantage is that the fiber layer does not have to be exactly dimensioned in relation to the area of the outer side of the profile to be laminated, but may well be larger in size, since this can be separated by means of simple finishing steps such as trimming. The lamination of the metal layer, as opposed to subsequent pinning, also has the manufacturing advantage that the lamination process can be integrated directly into the extrusion process.
In an exemplary embodiment of the profile according to the disclosure, the fiber layer comprises at least 50%, in particular at least 60%, 70%, 80% or at least 90%, natural fibers or is made from renewable raw materials to at least 50%, in particular at least 60%, 70%, 80% or at least 90%. Natural fibers are understood to be all fibers that come from natural sources, such as plants, animals or minerals, and/or are present without further chemical additives. Furthermore, at least 50%, in particular at least 60%, 70%, 80% or at least 90%, of the fiber layer may be made from renewable raw materials. For example, the fibers are regenerated fibers made from naturally occurring, renewable raw materials via chemical processes, for example cellulose-based.
According to an exemplary embodiment of the profile according to the disclosure, the fiber layer, in particular the fibers of the fiber layer, is selected from the group consisting of textile fibers, wood fibers, leather fibers and leather fiber materials. For example, the textile fiber ply is formed into a flat textile structure, such as a nonwoven, a woven fabric, in particular in plain weave, a knitted fabric, a braided fabric and/or felt. The textile may be, for example, woven cotton, velvet, printed cotton, catun, satin, silk, burlap, or the like. For example, the textile may be 100% polyester and/or woven and/or pigmented on at least one side and/or provided with a PUR coating. The plain weave has proven to be particularly preferred, especially with regard to post-processing. For example, common outdoor fabrics can be used. The plain weave has proved to be particularly advantageous, since fabric produced in this way tends to fray at the least during any trimming that may be necessary in the lamination process and/or when the profile is milled by a window manufacturer.
Wood fibers are generally elongated wood cells that serve to strengthen the wood and can be obtained from wood by mechanical defibration, also called wood pulps. The wood fibers or wood pulps can be further processed in the form of a veneer of, for example, a thickness in the range of 0.5 mm to 8 mm. Leather is generally defined as an animal hide made chemically durable by tanning, the natural fiber structure of which is largely preserved. Leather fibers that can be further processed into a leather fiber fabric, also known as lefa, are made from chrome shavings and shredded vegetable-tanned leather residues, natural latex, natural fats and tanning agents. For example, a leather fiber fabric of the applicant called Cabra may be used. The leather fiber cloth may have a percentage of total weight in terms of dry matter of the total leather fiber cloth of about 50 wt. % to 85 wt. %, a binder percentage of 7 wt. % to 40 wt. %, and a percentage of additives, such as pigments, auxiliaries, etc., in the range of 0 wt. % to 10 wt. %. For example, the leather fiber cloth may have a material moisture content in the range of 8% to 12%.
In a further exemplary embodiment of the profile according to the disclosure, the textile fibers have a fluid-repellent, in particular hydrophobic, and/or particle-repellent, in particular dirt- and/or dust-particle-repellent, property. A fluid-repellent and/or particle-repellent property is generally understood to be a tendency of the textile fiber layer to block fluids, such as water or the like, as well as particles from the environment. The fluid-repellent and/or particle-repellent property can result in fluid and/or dust particles at least partially beading off the textile fiber layer, in particular not entering the interior of the fiber layer. In this way, permanent adhesion of particles to the fiber layer can be avoided and a kind of self-cleaning effect can be generated, which can manifest itself, for example, by the particles preferably running off the fiber layer in the direction of gravity, in particular dripping off. Preferably, the fluid-repellent, in particular hydrophobic, and/or particle-repellent, in particular dirt- and/or dust-particle-repellent, finish is provided only on the outer side opposite the bonding or adhesive surface, in particular so as not to impair the adhesion to the adhesive built up.
The surface free energy, which in the case of liquids such as water is also the surface tension, can be used as a measure of the fluid-repellent, in particular hydrophobic, property. For example, the contact angle, also called the edge angle or wetting angle, between liquid particles, in particular liquid droplets, and the layer surface can be used to determine the surface energy. The surface free energy and/or contact angle can be determined, for example, by reference to DIN 5660-2 “Paints and varnishes—Wettability—Part 2: Determination of the free surface energy of solid surfaces by measuring the contact angle”, which is incorporated herein by reference in its entirety. The following relationship exists: a contact angle of less than 90° indicates a fluidphilic, in particular hydrophilic, surface property; a contact angle of about 90° indicates an indifferent surface with respect to, for example, hydrophobicity; a contact angle of greater than 90°, according to the present disclosure, indicates a fluid-repellent, in particular hydrophobic, surface property, depending on the fluid involved. To determine the surface energy based on the contact angle, for example, the Owens-Wendt-Rabel-Kaeble (OWRK) method known in the literature can be used. For the purposes of the present disclosure, dirt and/or dust particles have common particle or grain sizes that can act when the profile is used, for example, as a door and/or window part.
According to an exemplary embodiment of the profile according to the disclosure, the textile fibers are subjected to a treatment modifying the fluid-repellent and/or particle-repellent property of textile.
In exemplary embodiment of the profile according to the disclosure, the fluid-repellent and/or particle-repellent property is applied by spraying or coating, in particular printing, the textile fiber ply, in particular with a silane-based solution, such as a commercially available silane-based hydrophobizing agent. The fluid-repellent and/or particle-repellent property can be effected by an inorganic and/or organic surface modification of the fiber ply. For example, the coating agent may be diluted with water or organic solvents, such as alcohol, such that in particular a mixing ratio of 0.2%-25% coating agent and 75%-99.8% water or organic solvent is included, and may further be activated prior to the coating, spraying or printing process. For example, the fluid repellent and/or particle repellent property can be applied in such a way that after coating, spraying or printing, the so-called carrier liquid, i.e. the water or organic solvent, evaporates while the coating agent remains on the textile fiber layer. For example, the coating, printing or spraying is a surface modification that causes, for example, a change in the single fiber surface of the textile layer. In particular, the spraying, coating or printing can be understood macroscopically as a type of impregnation. According to an exemplary further development, a penetration depth of the fluid-repellent and/or particle-repellent property, preferably a coating, spraying or printing depth, can be adjustable or set by means of a contact pressure of a printing aid, such as a pressure roller, for printing the upstream layer.
In an exemplary embodiment, the textile fiber layer can be subjected to a treatment that alters the fluid-repellent and/or particle-repellent property of the textile in such a way that a bonding or adhesive surface of the textile fiber layer to be bonded to the profile, in particular to be bonded, is free from a treatment that alters the fluid-repellent and/or particle-repellent property. This can ensure that a sufficient adhesion build-up can be accompanied by the adhesive and that the adhesion build-up is not impaired by, for example, a coating. For example, it can be provided that a gradient results with respect to the fluid-repellent and/or particle-repellent property which, starting from an outer side of the textile fiber layer opposite the adhesive surface, decreases, for example continuously or abruptly, towards the adhesive side.
In an exemplary embodiment, the fiber ply is a leather fiber fabric having a leather content in the range from 50 wt. %, in particular from 65 wt. %, to 85 wt. % a binder content in the range from 7 wt. %, in particular from 10 wt. %, to 40 wt. %, in particular to 20 wt. %, and optionally a content of at least one additive, such as a pigment, of at most 10 wt. %, based on a total dry mass of the fiber ply.
In an exemplary embodiment of the profile according to the disclosure, the leather fiber material is provided with at least one pigmentation comprising at least one lightfast pigment. The at least one lightfast pigment ensures the reflection of radiation, in particular UV radiation, and thus improves the installation of the profile as a door and/or window part, even in outdoor applications. For the purposes of the present disclosure, the term “lightfastness” is used as a measure of the color fastness of a material, in particular a surface material. To determine lightfastness, it is analyzed whether the colors of the material, in particular the surface material, fade and/or change color when exposed to direct or indirect light. Lightfast materials, especially surface materials, do not lose any or hardly any of their color intensity even when exposed to direct sunlight. Sunlight with a high UV light content in particular has a decomposing effect on many materials, especially surface materials, which can lead to visible color changes. Such color changes have not only aesthetic but also technical disadvantages.
Extrusion profiles, for example made of plastic, for window and/or door parts, in particular window and/or door frame parts or window and/or door leaf parts, are affected by ultraviolet (UV) rays and infrared (IR) rays of varying intensity depending on the type of light. Since such extrusion profiles are permanently exposed to weather conditions, in particular UV radiation, for a long time, these rays can trigger reactions in the plastic material over time that lead to embrittlement and/or fading.
In an exemplary embodiment, the light fastness can be determined by any method familiar to the skilled person. For example, the lightfastness can be determined by an exposure method according to DIN 513: 1999-10, in which the color temperature is measured at a total irradiation power of about 12 GJ/m2 in the wavelength range from 300 nm to 800 nm. The individual steps of the methods for determining lightfastness and weather fastness will be dealt with in detail later in the examples.
In an exemplary embodiment, the fiber ply has a thickness of less than 1.0 mm, particularly a thickness in the range of 0.05 mm to 0.5 mm. For example, the leather fiber ply may have a ply thickness of about 0.35 mm, the textile fiber ply may have a thickness in the range of 0.1 mm to 0.3 mm, and the wood veneer fiber ply may have a thickness in the range of 0.35 mm. For example, the wood veneer fiber layer may be coated with a fabric layer. For example, the fabric layer can serve as an adhesive base for bonding.
In an exemplary embodiment, a connecting surface, in particular an adhesive surface, of the fiber ply to be connected to the profile is at least partially coated with a varnish.
A paint is generally a liquid or even powder coating material that is applied to the connection surface, for example sprayed on, rolled on or the like, and forms a generally continuous solid film from the surface.
In an exemplary embodiment of the profile according to the disclosure, the paint comprises polyester gel paint, epoxy resin paint, alkyd resin paint, acrylic paint, Polyurethane (PU) paint and/or a Polyvinylidene Fluoride (PVDF) coating.
According to an exemplary embodiment of the profile according to the disclosure, the adhesive is in particular a single-component hotmelt adhesive, in particular PU-based. Furthermore, a layer thickness of the adhesive can be greater than 60 g/sqm, in particular in the range from 80 g/sqm to 100 g/sqm. The layer thickness may further be in the range of 80 g/sqm to 100/sqm. The adhesive may be, for example, a so-called polyester polyurethane (PUR) hot melt, in particular a reactive PU hot melt, which, in addition to solidifying on cooling, also cures chemically, usually with the inclusion of moisture, and thus builds up a higher adhesion than a pure hot melt. Hot-melt adhesives of this type, also known as hot-melt adhesives, hot-melt glues or hot-melt adhesives, are generally solvent-free or water-free types of adhesive that are usually solid at room temperature, are present as a viscous liquid when heated and can thus be reliably applied to an adhesive surface to be bonded and, when cooled, form a solid bond between the bonding partners with reversible solidification. These adhesive types usually comprise thermoplastic polymers.
Particularly when using a textile fiber ply, the use of a varnish has proven to be advantageous with regard to post-processing and also with regard to cutting the textile fiber ply to length. The textile fibers tend to fray less when a varnish is applied, for example when it is necessary to cut the textile fiber ply to size and/or to cut out recesses for separate door and/or window parts, such as handles, fittings or the like.
According to exemplary embodiment of the present disclosure, which can be combined with the preceding aspects and exemplary embodiments, a method for producing an extrusion profile, in particular according to the disclosure, is provided. In the method according to the disclosure, an extrusion semi-finished product is produced by means of extrusion, in particular by means of co-extrusion, for example from plastic. The extrusion semi-finished product is generally said to have a uniform dimension in the extrusion direction and an identical cross-section. Furthermore, according to the disclosure, a fiber layer is at least partially laminated onto an outer side of the extrusion semifinished product by means of an adhesive. The method may be configured to produce a profile according to any of the exemplary embodiments or aspects of the present disclosure.
According to an exemplary embodiment of the present disclosure, so that the preceding aspects and exemplary embodiments can be combined, a door and/or window part, in particular a preferably fixed door and/or window frame part or a preferably movable door and/or leaf part is provided. The door and/or window part according to the disclosure comprises a profile according to the disclosure. Furthermore, it may be provided that the door and/or window part comprises a profile, in particular an extrusion profile, produced by means of the method according to the disclosure.
The aluminum screen 105 is adapted to a shape of the outer profile web 123 and the sealing web 125, so that the aluminum screen 105 completely covers the extruded plastic profile 103 toward the outer side. In the area of the glazing 107, the sealing gap 127 is formed between an angled end portion 129 of the aluminum screen 105 and the planar extension of the glazing 107. In this area, a glazing seal 113 specially formed for the extruded profile 103 is inserted. Compared to plastic extrusion profiles without aluminum screen 105, glazing seal 113 has been modified to seal the resulting different sealing gap dimension 127.
At the other end 131 of the aluminum screen 105, the aluminum screen 105 has an end portion that is U-shaped in cross-section and is so arranged around one end of the outer profile web 123. Through the angled ends 129, 131, the aluminum screen 105 is positively attached to the plastic extrusion profile 103, namely pushed on and clipped on.
With reference to
In contrast to the attached and latched aluminum panel 105, a fiber layer 6, for example made of textile, wood veneer or leather fiber material, is laminated onto the outer profile web 23 facing away from the building interior. The fiber layer 6 has a layer thickness of less than 1.0 mm, which is constant along its longitudinal extent and flexible due to its thin dimensioning. It is clear that the fiber layer 6 can also be laminated to an inner profile web 22 opposite the outer profile web 23, or that this can be additionally laminated with a fiber layer 6 in order to give the extrusion profile 3 a desired appearance on the inside as well. The manufacturing process will be discussed in detail later. The advantage of laminating the fiber layer 6 is in particular that, on the one hand, the fiber layer 6 lies directly on the extrusion profile 1, so that a particularly compact structure is provided. Furthermore, the fiber layer 6 can be dimensioned such that it substantially exclusively covers the visible area of the corresponding profile webs 23, 22 of the extrusion profile 3. It is not necessary for the fiber layer 6 to protrude into the sealing gap 27, for example in the area of the glazing, for example in order to ensure fastening as is the case with the aluminum screen 105. The same applies to the other end of the outer profile web 23, which the fiber ply 6 does not have to embrace. In the area of the glazing 7, this has a particularly advantageous effect, since recourse can be had to the standard glazing seals 13, so that no separate fabrications are necessary for the glazing seal 113, as is the case, for example, with the use of the aluminum screen 105. The fastening by means of lamination is significantly stronger and thus more durable than with the prior art clipping of, for example, additional aluminum screen 105.
With reference to
In the transfer area 47, the layer to be laminated, in particular fiber layer 6 made of textile, wood veneer or leather fiber material, for example, is supported on a roller 56. A strand 57 of the fiber layer 6 to be laminated is then continuously unwound from the roller 46 essentially synchronously and/or coordinated with the conveying F of the semi-finished extrusion product 41 and coated on one side on a laminating surface with adhesive, which is applied by means of a nozzle 59 upstream of a laminating roller 61, which presses the fiber layer 6 onto the plastic extrusion profile 3.
In contrast to prior art PVC film lamination onto plastic extrusion profiles, it has been found that the quantity of adhesive must be significantly increased to improve the adhesive effect with fiber layers, and in particular adhesive quantities in the range of 80 g/m2 are necessary. Furthermore, preheating of the fiber ply 6 is carried out immediately prior to adhesive application, and it has been found that significantly higher temperatures are necessary, for example in the range of 70° C. to 120° C. For good adhesion, it has been identified that a temperature of at least 55° C. must be maintained in the area of the laminating roller 61. Optionally, a hot air blower or other heat air generator 63 can be connected to the laminating roller 61.
Trimming can be carried out by means of a separation device 65. Subsequently, in particular in the area of the profile outlet 49, a further application of protective films can take place, which are provided by respective rollers 67, 69 and are applied to the upper and lower sides 22, 23 of the extrusion profile 1 according to the disclosure. This can be done by an adhesive applied to the protective films.
The features disclosed in the foregoing description, figures, and claims may be significant, both individually and in any combination, for the realization of the disclosure in the various embodiments.
To enable those skilled in the art to better understand the solution of the present disclosure, the technical solution in the embodiments of the present disclosure is described clearly and completely below in conjunction with the drawings in the embodiments of the present disclosure. Obviously, the embodiments described are only some, not all, of the embodiments of the present disclosure. All other embodiments obtained by those skilled in the art on the basis of the embodiments in the present disclosure without any creative effort should fall within the scope of protection of the present disclosure.
It should be noted that the terms “first”, “second”, etc. in the description, claims and abovementioned drawings of the present disclosure are used to distinguish between similar objects, but not necessarily used to describe a specific order or sequence. It should be understood that data used in this way can be interchanged as appropriate so that the embodiments of the present disclosure described here can be implemented in an order other than those shown or described here. In addition, the terms “comprise” and “have” and any variants thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or equipment comprising a series of steps or modules or units is not necessarily limited to those steps or modules or units which are clearly listed, but may comprise other steps or modules or units which are not clearly listed or are intrinsic to such processes, methods, products or equipment.
References in the specification to “one embodiment,” “an embodiment,” “an exemplary embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
The exemplary embodiments described herein are provided for illustrative purposes, and are not limiting. Other exemplary embodiments are possible, and modifications may be made to the exemplary embodiments. Therefore, the specification is not meant to limit the disclosure. Rather, the scope of the disclosure is defined only in accordance with the following claims and their equivalents.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102020108568.0 | Mar 2020 | DE | national |
