Composite profile and method for making a composite profile for frames of wall elements, doors and windows

Description

[0001] The invention relates to a composite profile for frames of wall elements, doors or windows and to a method for manufacturing the composite profile with the features of the preamble of the independent claims.

[0002] These composite profiles are particularly useful for providing thermal insulation to frame structures. Another application for such profiles is in fire protection.

[0003] EP 1 020 608 A1, for example, shows a composite profile with two approximately box-shaped metal profiles and an insulating material arranged between them. The metal profiles are connected to each other by metal bolts that penetrate the insulating material. These metal bolts are welded to the parallel end faces of the metal profiles. An intumescent building material is attached directly to the inwardly offset lateral surface of the insulating material.

[0004] German patent DE 195 26795 describes a composite profile comprising two metal profiles with insulating material arranged between them. The metal profiles are joined by welding individual metal webs or a sheet extending longitudinally along the profile to the side walls of the metal profiles. One embodiment described in DE 195 26795 relates to a composite profile in which the insulating material is offset inwards relative to the side walls of the metal profiles. A connecting sheet has a stepped end cap, which allows the connecting sheet to be positioned and placed precisely against the metal profiles. The recess created by the end cap can be covered by a strip. A disadvantage of this composite profile is that at least part of the connecting sheet protrudes beyond the side walls. Handling and use of such a profile can therefore be difficult.Furthermore, this composite profile arrangement has a negative impact on the cladding of the composite profile. From an aesthetic point of view, such a composite profile is also poorly suited for use in the frames of wall elements, doors, or windows.

[0005] It is therefore an object of the present invention to avoid the disadvantages of the known method, in particular to create a device and a method of the type mentioned above which provides a simple way of receiving various side elements. Furthermore, no protruding elements should complicate the handling of the composite profile. Finally, the composite profile should be easy to manufacture and meet high requirements regarding statics and rigidity.

[0006] EP 1 510 643 A discloses a composite profile for frames of wall elements, doors or windows with at least two metal profiles arranged at a distance from each other and with connecting parts made of metal connecting the metal profiles.

[0007] According to the invention, these problems are solved with a composite profile having the features of claim 1. The composite profile essentially consists of at least two metal profiles arranged at a distance from one another and connecting metal elements connecting them. The metal profiles each have opposing end walls and opposing end wall sections to which the connecting elements are attached, preferably welded, wherein the end wall sections lie on a plane that is parallel to the respective end wall or forms an angle of inclination between 10° and 60° with the respective end wall. A preferred metal profile can, for example, have an end wall and side walls extending approximately perpendicular to it. An end wall section adjoins a side wall. Each connecting element has a side section with end sections.Each connecting element is attached to the adjacent end wall sections of the metal profiles at its end faces. The end face of a connecting element can, for example, be angled relative to the side face such that it defines a preferred contact surface with the corresponding end wall section of the metal profile. Of course, it is also conceivable that the end face has a curvature in cross-section, particularly an arc shape. In this case, only an approximately linear contact zone with the end wall section of the metal profile would be formed. The connecting elements can be arranged offset inwards with respect to a side wall of the metal profiles, advantageously creating a recess for receiving side elements. Preferably, the connecting elements are arranged in the composite profile such that their end faces outwards.Side elements can include, for example, fire protection elements, cover strips, seals, or fittings. The metal profiles can be designed as open profiles, with their side walls advantageously facing each other. In this way, a single-chamber composite profile can be formed. Depending on the application, insulation and / or fire protection materials can be arranged in the resulting cavity of the composite profile. The end wall sections of the metal profiles can run parallel to each other, with the end wall sections of each metal profile preferably lying on the same plane. Such an arrangement has the advantage that the distance between the metal profiles can be predetermined. The angled arrangement of the end wall sections of the metal profiles also ensures that inaccuracies in fit can be compensated for when inserting the connecting parts. This allows the manufacturing process to be significantly optimized.

[0008] The metal profiles and / or connecting parts can be made of sheet metal. The profiles can thus be easily formed using a bending and / or folding process. A roll forming process would be particularly advantageous for manufacturing the profiles.

[0009] The metal profiles and / or connecting parts can be made of steel. A composite profile made of steel is characterized by particularly good fire protection properties. Since steel is relatively easy to form and weld, the composite profile can be manufactured cost-effectively. Even higher fire ratings could be achieved by using stainless steel for the profiles. It is particularly advantageous if the metal profiles are made of steel, for example, structural steel, and the connecting parts are made of higher-grade stainless steel. In this way, the thermal insulation and fire protection properties of the composite profile can be optimized at relatively low cost.

[0010] In another embodiment, at least one of the metal profiles is a C-shaped profile in cross-section. Such profiles can be manufactured particularly cost-effectively. Of course, it is also conceivable that the metal profiles, or at least one of them, are designed as a closed profile. In this case, the two end wall sections of the metal profile would be connected to each other.

[0011] The connecting elements can have straight or angled webs to reduce heat flow between the metal profiles. This arrangement is characterized by particularly good thermal insulation properties. Webs can be formed, for example, by providing a series of openings in the side section of the connecting element, with the row running longitudinally along the composite profile. The webs or openings could, for instance, be created by processing a sheet metal part using a punching or laser cutting process.

[0012] It is advantageous if end sections are attached to the end faces of the connecting parts, preferably oriented towards each other. This creates a convenient space for receiving side elements, which would be partially concealed. The side elements cannot be damaged, scratched, or dislodged during handling of the profiles. A further advantage of this arrangement is that additional fixing of the side elements to the connecting parts, for example by gluing, is no longer necessary. The end sections could also serve as a locking mechanism for snapping the side elements into place.

[0013] It is particularly advantageous if the end sections run approximately perpendicular to the side section of the connecting piece and if the end sections connect to the end sections at approximately perpendicular angles. The two end sections of a connecting piece can lie in the same plane. However, a stepped arrangement of the end sections is also conceivable. Of course, other designs of connecting pieces are possible instead of angled end and end sections. For example, the connecting piece can be bent or rounded at its ends to form a U-shape. The end section and end section could, for instance, lie on a circular arc in cross-section. It is also possible for the end section and end section to form a V-shape.

[0014] The end section of the connecting element can extend longitudinally along the connecting element (or composite profile). Such a continuous end section can be easily manufactured from a long rectangular sheet. Alternatively, the end section can also be formed by a plurality of individual sections arranged in a row running longitudinally along the connecting element (or composite profile). The individual sections are separated from each other by cutouts. Preferably, uniform spacing is provided between the individual sections.

[0015] Fire protection elements, cover strips, seals, and / or fittings can be arranged in the space defined by the end sections of the connecting piece. By arranging such side elements, the composite profile can be optimally aligned for a specific application or purpose. Fire protection elements could, for example, contain materials that expand under the influence of heat. Such materials can expand their volume many times over at elevated temperatures, thus providing a better seal for the composite profiles in the event of a fire. A particular advantage of arranging fire protection elements arises especially when combined with connecting pieces that have straight or angled webs.

[0016] Fire- and / or heat-resistant insulation material can be placed inside the composite profile formed by the metal profiles and connecting elements. This further increases the fire resistance rating. Depending on the intended use of the composite profile, its interior is filled completely or only partially with insulation material. For example, in a single-chamber composite profile, the insulation material can extend from the end wall of one metal profile to the end wall of the other. Alternatively, insulation material, such as a fire-resistant board, could be placed in the area between the connecting elements. In this case, the end faces of the insulation material would advantageously rest against the end wall sections of the metal profiles. Of course, insulation material could also be placed within a single metal profile.This insulating material would then be bounded at the end face by the end wall and the end wall sections of the metal profile. Of course, for further optimization, several sections made of different insulating materials could be used inside the composite profile.

[0017] To manufacture the composite profiles, the metal profiles and connecting pieces must be positioned relative to each other so that the end face sections of the metal profiles rest against the end faces of the connecting pieces. Due to the manufacturing process, the relatively long profile components (e.g., 6 m in length) may be slightly bent due to internal stresses. Positioning and adjusting the profile components relative to each other can be achieved under relatively high forces. In practice, however, it has been shown that it can be advantageous to selectively weaken the connecting pieces at certain points to increase their adaptability. This reduces the amount of (pressing) force required. The connecting pieces can be designed to achieve this by having several notches or breaks arranged in a row.Such a cut is particularly advantageous when positioned in the area of ​​a base created by the preferably triangular opening for forming the webs. The production of composite profiles can be considerably simplified in this way, since such connecting elements can compensate for any inaccuracies in fit without requiring much force.

[0018] Another aspect of the invention relates to a method for manufacturing a composite profile for frames of wall elements, doors, or windows. Two metal profiles, each having opposing end walls and facing end wall sections, and connecting parts with a side section and angled end sections at its ends, wherein the end wall sections lie on a plane parallel to the respective end wall or form an angle of inclination between 10° and 60° to the respective end wall, are formed by bending and / or folding processes. The metal profiles and the connecting parts are positioned relative to each other such that the end wall sections of the metal profiles abut the end sections of the connecting parts. The metal profiles and the connecting parts are then joined together by a welding process. In this way, the composite profiles described above can be manufactured particularly easily.

[0019] Further individual features and advantages of the invention will become apparent from the following description of the exemplary embodiments and from the drawings. These show: Figure 1: A cross-section through a composite profile according to the invention; Figure 2: A cross-section through a composite profile according to a second embodiment; Figure 3: A cross-section through a composite profile according to a third embodiment; Figure 4: An embodiment of a composite profile according to Figure 2 with insulating material, Figure 5 a cross-section through a composite profile according to an alternative embodiment, Figure 6 a cross-section through another composite profile, Figure 7 a side view of a connecting part, Figure 8 a side view of the connecting part according to Figure 7 for a composite profile according to Figure 5 Figure 9 shows a side view of the connecting part for a composite profile according to Figures 1 to 4as well as 6, Figure 10a a detailed partial view of the cross-section of a composite profile according to a further embodiment, Figure 10b a detailed partial view of the cross-section of a composite profile according to an alternative embodiment to Figure 10a Figure 10 shows a detailed partial view of the cross-section of a composite profile in a further alternative embodiment. Figure 10a Figure 11: a perspective view of a section of a connecting part; Figure 12: a perspective view of a section of an alternative connecting part; Figure 13: an alternative side view of a connecting part; Figure 14: an enlarged view of a cam and a [missing information] according to Figure 13 (Detail B), and Figure 15 an alternative embodiment of the cam according to Figure 14 .

[0020] Figure 1Figure 1 shows a composite profile, which essentially consists of two metal profiles 2 and 16 and two connecting parts 3. The metal profiles 2 and 16, arranged at a distance A from each other, are designed as open profiles with end wall sections 4 facing each other. The connection with the connecting parts 3 creates a single-chamber profile 1 with a cavity 10. One connecting part 3 has a side section 5 that bridges the distance A between the metal profiles 2 and 16. At the ends of the connecting part 3, end sections 6 are provided that are angled at right angles to the side section and face outwards. The end sections 6 are clearly in contact with the corresponding end wall sections 4 of the metal profiles 2 and 16 and are welded to them.Of course, other fastening methods, such as screw or rivet connections, could also be used.

[0021] The connecting elements 3 are evidently offset inwards from the side walls 18 of the metal profiles 2 and 16, thus forming a recess. The end wall sections 4 are each directed outwards. Side elements such as fire protection elements, cover strips, or seals can be advantageously arranged in the recess thus created. Fittings, for example, strike plates or a lock, are also suitable.

[0022] The metal profiles 2 and 16, as well as the connecting parts 3, are preferably made of steel, which allows the respective profiles to be easily formed and welded together. The metal profile 2 has a C-shape in cross-section. The metal profile 16 is also essentially C-shaped. However, for use as a frame element for doors or windows, a folded-over end is provided on the end face 16.

[0023] The connecting parts 3 according to Figure 2The two versions differ from Figure 1 in that end sections 7 are attached to the end sections 6 and are directed towards each other. A fire protection element 9, for example a fire protection strip that expands when exposed to heat, is arranged in the space thus defined by the end sections 7 of the connecting part 3. The end sections 7 allow the fire protection elements or other side elements to be held in the connecting part 3 without additional fasteners (such as adhesive bonds). Depending on the design of the side elements, the end sections 7 can also be used as lugs for snap-fit ​​or latching connections. Figure 2 It is further evident that in the area of ​​the side sections 5 of the connecting parts 3 webs 12 are provided (see below). Figures 7 and 9 ).

[0024] Figure 3Figure 1 shows a composite profile 1 in whose interior or cavity 10 an insulating material 11 is arranged. The insulating material 11 preferably consists of fire- and / or heat-resistant materials. In the present case, the insulating material 11 is rectangular and extends from one end wall 17 of the metal profile 2 to the opposite end wall 17 of the metal profile 16. The insulating material 11 is held in position laterally by the connecting elements 3. The side surfaces of the insulating material 11 abut against grooves 14 of the connecting elements (see following). Figures 7 and 9 Additionally (or alternatively), the free ends of the end wall sections 4 of the metal profiles 2 and 16 could be used to position the insulation material 11. In the space 8 bounded by the end sections 7 of the connecting parts 3, the same could of course be done here as in Figure 2 shown - side elements arranged.

[0025] As from Figure 4 As can be seen, the insulating material 11 can be arranged in the cavity 10 of the composite profile 1 in the area defined by the connecting parts 3. For this purpose, the free ends of the end wall sections 4 project inwards towards the connecting parts 3, allowing the end faces of the insulating material to rest against the end wall sections 4. It is also conceivable to arrange additional or alternative insulating materials in the area defined by the metal profiles 2 and 16. These insulating materials can be made of the same or different materials as the insulating material 11.

[0026] In the previously shown composite profiles 1, the end wall sections 4 of the metal profiles 2 and 16 run parallel to each other. How Figure 5As shown, the end wall sections 4 can also be arranged at an angle. The angled end wall sections 4 form the free end of the metal profiles. A second end wall section 20 is arranged between the side walls 18, which run at right angles to the end walls 17, and the end wall sections 4. This end wall section 20 rests against the side wall 18 and runs approximately parallel to it. This forms a fold. This fold can be produced by folding / flanging. As shown in Figure 5 As can be seen, the connecting part 3 cannot be placed laterally against the end wall sections 4. Rather, the connecting part 3 must be inserted or pushed in longitudinally from one end of the metal profiles held at a distance A. The end wall sections 4 lie on a plane that forms an angle of inclination α with planes running parallel to the corresponding end wall 17. In the exemplary embodiment according to Figure 5The angle is approximately 30°. Consequently, the end sections 6 of the connecting parts 3 are angled at 60° relative to the side section 5. With regard to weldability and stability of the composite profile, the angle α lies between 10° and 60°, preferably between 20° and 45°. The in Figure 5 The side elements 9 attached to the connecting parts 3 are designed such that the outer surface of the side element lies on the plane of the side walls 18 of the metal profiles 2 and 16.

[0027] Figure 6 Figure 1 shows a composite profile 1 in which the metal profiles 2 and 16 are designed as closed profiles. The end wall sections are connected to each other in such a way that a closed inner end wall 19 is formed. An insulating material 11 is arranged between the end walls 19 and the connecting parts 3.

[0028] As can be seen from the side view of connecting part 3 according to Figure 7As can be seen, the connecting element is designed as a component extending longitudinally along the composite profile, for example, a sheet of steel, but preferably of stainless steel. A composite profile with metal profiles made of steel and connecting elements made of stainless steel is characterized by particularly good thermal insulation and fire protection properties. The connecting elements 3 have inclined webs 12, which are formed by creating openings 13 arranged in a series in the connecting element in the area of ​​its side section 5. Furthermore, in the Figure 7 as well as 8 and 9, it can be seen that a bridge 12 has inwardly directed beads 26.

[0029] As the Figures 10a and 10bAs shown, the ends of side section 5 do not necessarily have to be formed by bends. The connecting part 3 is bent at its ends, thus defining a U-shape. The end section 6 and the end section 7 lie on a circular arc. In this case, only an approximately linear contact zone would be formed with the end wall section of the metal profile. This can have advantages when welding to the metal profiles. Figure 10c Front section 6 and end section 7 define a V-shape.

[0030] In Figure 11 The end section 7 of the connecting part 3 extends in its longitudinal direction. Instead of a continuous end section, this can be - as Figure 12- can also be formed by a plurality of individual sections 21, which are separated from each other by recesses 22. The individual sections 21 are arranged in a row running longitudinally along the connecting part. The approximately rectangular individual sections 21 are advantageously arranged at uniform intervals from each other.

[0031] Figure 13 shows a variant of the connecting part according to Figure 7 The connecting part evidently has 3 cams 23 for fixing insulating material arranged in the cavity. Such cams are described, for example, in EP-A-1 510 643. As can be seen from Figure 14As can be seen, a recess 25 is provided in the area of ​​each cam 23 to facilitate inward deformation of the cam. Furthermore, each cam 23 is associated with a notch or slot 24. The connecting part 3 is held together in the area of ​​the cam solely by the notch or slot 24. Of course, it is also conceivable to provide notches or slots without cams. With the aid of these notches, the connecting part can be easily fitted between the metal profiles. Any inaccuracies in fit can thus be compensated for without applying large pressing forces. These would preferably also be compensated for – as in Figure 13As shown, the openings are arranged alternately at the top and bottom of a base 27 of an approximately triangular opening 13. Between the recess 25 and the end section 6, a further recess 26, advantageously in the form of a circular hole, is provided. Figure 15 As shown, the recess 25 can be designed as a circular hole. This is in comparison to Figure 14 further offset to the outside, so that cam 23 is fully formed.

Claims

1. Composite profile (1) for frames of wall elements, doors or windows, comprising at least two metal profiles (2, 16) arranged at a distance (A) from one another and comprising connecting parts (3) which are made of metal and connect the metal profiles, wherein the metal profiles (2, 16) each have opposite end walls (17) and end wall portions (4) directed toward one another, to which the connecting parts (3) are attached, preferably welded, wherein the end wall portions (4) lie on a plane which extends parallel to the corresponding end wall (17) or forms an inclination angle (α) of between 10° and 60° with respect to the corresponding end wall (17), and wherein each connecting part (3) has a lateral portion (5) having end portions (6) which are angled or are provided with a bend in cross section for defining a contact surface or linear contact zone with respect to the corresponding end wall portion (4), wherein, in the region of the end portions (6), the connecting part (3) is attached to the adjacent end wall portions (4) of the metal profiles (2, 16).

2. Composite profile according to claim 1, characterized in that the metal profiles (2, 16) and / or the connecting parts (3) consist of sheet metal.

3. Composite profile according to either claim 1 or claim 2, characterized in that the metal profiles (2, 16) and / or the connecting parts (3) consist of steel.

4. Composite profile according to any of claims 1 to 3, characterized in that at least one of the metal profiles (2, 16) is a profile that is C-shaped in cross section.

5. Composite profile according to any of claims 1 to 4, characterized in that the connecting parts (3) have straight or obliquely extending strips (12) for reducing the heat flow between the metal profiles (2, 16).

6. Composite profile according to any of claims 1 to 5, characterized in that terminal portions (7) adjoin the end portions (6) of the connecting parts (3), which terminal portions are preferably directed approximately toward one another.

7. Composite profile according to claim 5, characterized in that the end portions (6) each extend approximately perpendicularly to the lateral portion (5) of the connecting part (3), and in that the terminal portions (7) adjoin the end portions (6) approximately perpendicularly.

8. Composite profile according to either claim 6 or claim 7, characterized in that at least one of the end portions (6) of the connecting parts (3) is formed by a plurality of individual portions (21) which are arranged in a row extending in the longitudinal direction of the connecting part.

9. Composite profile according to any of claims 6 to 8, characterized in that lateral elements (9) are arranged in the space (8) delimited by the terminal portions (7) of the connecting part (3), the lateral elements being selected from the group of cover strips, seals, fittings or fire protection elements, in particular fire protection elements which expand when exposed to heat.

10. Composite profile according to any of claims 1 to 9, characterized in that a fire and / or heat-resistant insulation material (11) is arranged in the interior (10) formed by the metal profiles (2, 16) and the connecting parts (3).

11. Method for producing a composite profile (1) for frames of wall elements, doors or windows from two metal profiles (2, 16) which each have opposite end walls (17) and end wall portions (4) directed toward one another and connecting parts (3) which connect said end wall portions and have a lateral portion (5) and angled end portions (6) at the ends of said lateral portion, in particular according to any of claims 1 to 10, wherein the end wall portions (4) lie on a plane which extends parallel to the corresponding end wall (17) or forms an inclination angle (α) of between 10° and 60° with respect to the corresponding end wall (17), wherein the metal profiles (2, 16) and the connecting parts (3) are each formed by folding and / or bending processes, and wherein the metal profiles (2,16) and the connecting parts (3) are positioned such that the end wall portions (4) of the metal profiles (2, 16) abut the end portions (6) of the connecting parts (3), and the metal profiles (2, 16) and the connecting parts (3) are connected to one another by means of a welding process.