Method for manufacturing a spacer profile

Abstract

The invention provides a method for producing a spacer profile. In a first step, a profile body and a first functional element are respectively produced separately. In a later step, the profile body and the first functional element are fed to an ultrasonic welding device in the longitudinal direction of the spacer web to be formed, in which the profile body and the first functional element are connected to one another in a material-locking manner in the form of a welded connection. The ultrasonic welding device comprises a welding head which has a recess for guiding the functional element during the formation of the welded connection. During the formation of the welded connection, the profile body and the functional element are combined into a predefined first cross-sectional geometry and are then guided in this cross-sectional geometry or, if required, in a second cross-sectional geometry which differs therefrom, until the plastic material of the welded connection has cured to such an extent that the profile body and the first functional element are fixed in the predefined cross-sectional geometry.

Description

Technical Field

[0001] This invention relates to a method for manufacturing insulating profiles, particularly insulating profiles used in the manufacture of windows, doors, and facade elements, and to insulating profiles manufactured according to this method. The insulating profile to be manufactured includes an insulating tab made of a first polymer material. The insulating tab includes a profile body and first functional elements extending along the longitudinal direction of the insulating profile, wherein the first functional element is engaged with the insulating tab material in a contact area.

[0002] The insulating profiles mentioned at the beginning are used in a wide variety of applications in the manufacture of metal-plastic composite profiles, where the insulating profiles are used for thermal and / or sound insulation of the composite profiles, and typically connect two metal profiles to each other.

[0003] The insulating profiles made according to the invention are also used as so-called schikane as sills in sliding systems for large windows or doors. Finally, the insulating profiles according to the invention are suitable as facade spacers, particularly for maintaining a distance between adjacent glass panes or other facade panels in facades and glass roof structures, and for filling gaps present therebetween if necessary. Background Technology

[0004] To date, the aforementioned isolation profiles have typically been manufactured according to specific geometric pre-defined quantities by the customer. This requires the use of expensive methods to create a costly base forming tool, which is then used to precisely produce the target profile of the isolation profile as specified by the customer.

[0005] Another drawback of this traditional approach is its lack of flexibility, in addition to high tooling costs, to accommodate specific desires to change the geometry of the composite. Therefore, for example, it is not easy to increase the apparent width of the metal-plastic composite while retaining the insulating profile, without sacrificing the insulating function.

[0006] This problem can be addressed using a variety of solutions in existing technologies.

[0007] It should be noted in principle that such isolation profiles are safety-related components, and they undergo qualified testing in Germany, for example, according to DIN EN14024.

[0008] The following insulating profiles are known, in which foam is applied afterward. These foams are fixed to the insulating profile either material-locked or form-locked. For example, EP 1 347 141 A1 describes an insulating profile combined with foam strips of different heights.

[0009] DE 10 2010 064 034 A1 also describes a metal-plastic composite profile whose performance is optimized by post-application of foam material.

[0010] Alternative solutions exist in the market, differentiated by various variations of the insulating foam. These foams face high demands, particularly when subjected to powder coating processes within profile composites. Only a handful of foam technologies can withstand the multiple pretreatment chemical baths and subsequent baking during coating, resulting in temperatures exceeding 200°C. Furthermore, these foams must possess low thermal conductivity, be inexpensive, environmentally friendly, and reusable. To date, no system meets all these requirements.

[0011] Other processing methods include applying functional elements in the form of protrusions (Fahnen), or subsequently constructing a hollow chamber structure, for example, using polymer or metal materials.

[0012] As is known from DE 296 21 419U1, isolation profiles can be variably manufactured by clamping U-shaped profiles onto a base profile. These isolation profiles can be easily matched to optimize the profile composite in terms of isolation effect. However, a drawback of this method is the need for a so-called fixed nose on the base profile to establish the clamping connection, wherein this nose also immutably determines the fixed positioning of the hollow chamber to be formed.

[0013] DE 195 28 498C1 and DE 10 2012 009 838 A1, based on this document, describe the possibility of manufacturing composite profiles by subsequently applying the protrusion to the isolation profile / base profile.

[0014] DE 195 28 498C1 describes for this purpose protrusions made of materials such as polyamide or polyester, either injection molded or co-extruded, as well as metal protrusions. However, this document does not demonstrate how metal protrusions can be permanently and securely attached without significantly impairing thermal insulation and mechanical properties, especially, for example, transverse tensile strength according to DIN EN 14024.

[0015] DE 10 2012 009 838 A1 describes an insulated profile with a protruding structure having a plurality of parallel-extending insulated hollow chambers, wherein the protrusions may be made, for example, of a plastic film material.

[0016] The thin wall thickness of the film material combined with the hollow chamber makes such products significantly disadvantageous in the event of a fire compared to other solutions. The protrusions are applied, for example, by bonding or welding. Furthermore, a disadvantage of the freestanding thin plastic film is its susceptibility to bending. Therefore, during transport and storage within shipping containers, the protrusions made of freestanding film may clump, bend, and permanently deform due to the weight of the profile. This is a typical criterion for rejecting the product.

[0017] DE 195 11 081A1 describes a composite profile having an insulating profile made of plastic and a lateral protrusion of a bridged, heat-insulating metal.

[0018] EP 2 527 580 A1 describes a composite profile in which the function of the lateral protrusion is achieved by separate profiles fixed to one of the metal shells of the composite profile.

[0019] In isolation profiles, the protrusion is extended via an adapter, as described, for example, in EP 2 432 960 A1. However, it is clear from the cross-sectional area of ​​the described and illustrated profile geometry that this solution is only feasible with high material input.

[0020] For example, as known from WO 2015 / 189348 A1, there are various types of isolation profiles that function as spacers for facade elements.

[0021] Methods for welding continuous or wide-area materials using ultrasonic waves are widely used, particularly in the consumer goods industry, and for example, in the manufacture of diapers, film bags, or foam packaging. Here, a thin plastic film is typically used as a so-called splice joint, which is then welded in-line using a rolling welding head or a (traveling) beat-type welding head punch. However, this welding method is unsuitable for manufacturing plastic films with thicknesses in the millimeter range, such as spacers, at high output speeds and with high dimensional accuracy. In known ultrasonic welding methods, the main problems are the relatively low energy input of the rolling welding head due to its small effective contact area (derived from the head's radius), or significant deformation of the product at offset locations when using a beat-type punch welding head. Summary of the Invention

[0022] Therefore, the object of the present invention is to provide a method for manufacturing isolation profiles in an economical manner and in a way that can easily meet customer-specified requirements for the functionality of the isolation profiles.

[0023] This task is solved according to the method according to the invention.

[0024] In the method for manufacturing an insulating profile according to the invention, in a first step, a profile body and a first functional element are separately formed and provided, wherein, in a subsequent second step, the profile body and the first functional element are conveyed along the longitudinal direction of the insulating strip to be formed to an ultrasonic welding apparatus, in which the profile body and the functional element are materially locked together to form a welded connection, wherein the ultrasonic welding apparatus includes a welding area equipped with one or more welding heads. The welding head(s) have recesses within which the functional element is guided during the formation of the welded connection.

[0025] During the formation of the welded connection, the profile body and the first functional element are combined into a pre-given first cross-sectional geometry viewed perpendicular to the longitudinal direction, and then guided in the pre-given first cross-sectional geometry or, if necessary, in a pre-given second cross-sectional geometry viewed perpendicular to the longitudinal direction that differs from the first cross-sectional geometry, until the plastic material of the welded connection is cured to the extent that the profile body and the first functional element are fixed in the pre-given cross-sectional geometry.

[0026] The latter typically occurs when the polymer material is cooled to below its crystallization melting point or softening temperature in the area of ​​the welded joint.

[0027] The ultrasonic frequency used in the ultrasonic welding according to the invention is, for example, in the range of 20 kHz to 40 kHz.

[0028] On one hand, there is the profile body or the isolation plate, and on the other hand, there is the first functional element, which will be referred to as the splicing and mating part in the following text.

[0029] In the method according to the invention, the profile body and the first functional element are continuously or intermittently fed to the ultrasonic welding equipment.

[0030] Here, the profile body and / or the first functional element may be provided as a continuous material or as a bar (Stangenware).

[0031] Each of the two aforementioned aspects has ensured great flexibility in the manufacturing process.

[0032] According to the invention, an isolation tab is first manufactured having one (or more, if necessary) profile body and optional edge sections formed onto the profile body, wherein one or more first functional elements and / or other functional portions, for example in the form of so-called protrusions, are subsequently locked together with the isolation tab material. These functional elements are typically also made of polymeric material.

[0033] Typically, the isolation strip has two edge sections that are formed opposite each other onto the profile body, perpendicular to the longitudinal direction of the isolation profile.

[0034] The material locking connection between the profile body and one or more first functional elements can be carried out continuously, i.e., in particular, along the longitudinal direction of the isolation profile, or it can be carried out intermittently or segmentally at multiple successive positioning points.

[0035] In addition, the isolation tab may have two or more profile bodies, wherein at least one edge segment is typically formed onto one of the profile bodies.

[0036] The wall thickness of the insulating profile made according to the present invention is typically from about 0.6 mm to about 2.5 mm, preferably from about 0.7 mm to about 2 mm. However, it can be thicker in special applications.

[0037] The first functional element preferably extends obviously from the surface (in the vertical direction) of the profile body or edge segment, for example, about 3 mm or more.

[0038] Typically, the wall thickness of the first functional element is in the range of about 0.6 mm to about 2 mm or greater, depending on the function assigned to the first functional element.

[0039] The function of the first functional element is, in particular, to transmit force, to house a sealing element such as an elastomeric sealing element, and to reduce or suppress convection flow or other conditions in a so-called protrusion (that is, a structural element used to divide a cavity). Therefore, the shape of the functional element may include or have the following shapes: protrusion, hook, nose, groove, T-shaped flip, or arrow, etc.

[0040] Therefore, the functional element is preferably made of a material, especially a polymer material, having an elastic modulus of, for example, about 2000 MPa or greater, preferably about 3000 MPa or greater, and / or a tensile strength of about 40 MPa or greater.

[0041] The connection between the first functional element and the isolation plate can be made directly, if necessary, on the protrusion constructed on the isolation plate.

[0042] By means of the method according to the invention, insulating profiles can be produced economically in terms of both batch size (now even small batches can be manufactured for customers at a relatively low cost) and the raw materials used, without the need to unnecessarily increase the diversity of raw materials in the product. This provides customers with advantages in both economics and technical performance, and facilitates the handling and reliable application of the insulating profiles. The processing of the profiles here specifically includes:

[0043] - (e.g., transported and stored loosely or bundled in transport containers used for bars);

[0044] - Cutting, sawing, and milling to, for example, cut profiles to length, sharpen, pierce, or pack profiles to fit applications;

[0045] - To condition the food to control moisture content or to regulate specific storage and aging conditions;

[0046] - For example, using aqueous dispersions, solutions or solvents, or chemicals to perform cleaning and pretreatment steps, especially for preparing coating processes (painting, bonding, etc.);

[0047] - Performing coating, especially painting, such as powder coating baking at temperatures up to 200°C or up to 220°C; and

[0048] - Apply or place foam or foaming material.

[0049] Here, the insulating profile can be manufactured with particularly high dimensional accuracy, that is, low tolerance, and especially with high parallelism among the various components of the insulating profile. This greatly facilitates the processing of the insulating profile into a composite profile.

[0050] The polymer material of the separator is preferably a thermoplastic or weldably modified thermosetting material (e.g., by using a polymer blend having separate thermoplastic regions). In addition to one or more polymers, the polymer material may also additionally contain reinforcing materials, especially fibers, particularly preferably in the form of glass fibers, other fillers, additives, dyes, etc.

[0051] The fiber-reinforced polymer material preferably comprises reinforcing fibers having a weight percentage composition of about 5% to 60%, more preferably about 20% to 50%. This is particularly applicable to the polymer material of the profile body of the insulating profile according to the invention.

[0052] Preferably, in the method according to the invention, the profile body and functional elements are positioned relative to each other in a predetermined, changeable relative position as needed, and guided in the longitudinal direction within the guide zone by means of a first guiding device before passing through the welding zone.

[0053] Furthermore, preferably according to the invention, after passing through the welding zone, the profile body and functional elements are positioned relative to each other in a predetermined, changeable relative position as needed, and guided in the longitudinal direction by means of a second guiding device in the area of ​​the holding zone.

[0054] Alternatively, the profile body and functional elements are pressed together with a predetermined force when passing through the welding zone and optionally also when passing through a second guide device immediately following the welding zone.

[0055] Preferably, the first functional element is provided with one or more melting elements, which extend as protrusions from the surface of the contact area of ​​the first functional element. The protrusions preferably extend from the surface by about 3 mm or less, more preferably by about 1.5 mm or less. Advantageously, the protrusions extend from the surface by about 0.2 mm or more, preferably about 0.4 mm or more.

[0056] According to a variation of the method of the invention, the profile body and the first functional element are conveyed at an acute angle to each other relative to the longitudinal direction, wherein the acute-angled guide extends at least over a portion of the welding area and, if necessary, over portions of the first and / or second guide devices. This angle is primarily determined by the height h of the energy direction guide. ERG The influence of the length of the weld zone, typically about 5° or less, preferably about 3° or less, especially when averaged over the entire length of the weld zone.

[0057] Preferably, in the method according to the invention, ultrasonic welding is performed as near-field welding, wherein the welding head has direct contact with the first functional element, and wherein, preferably, the welding head is arranged at a distance of at most about 6 mm or less from the profile body.

[0058] Preferably, the welding area has a length of approximately 5 cm to approximately 50 cm, and may have more than one welding head if required.

[0059] According to the method of the invention, within the welding zone, one or more welding heads can occupy different angular positions relative to the profile body with reference to the longitudinal direction, wherein the angular positioning is continuously and / or progressively changed, and the spacing between the one or more welding heads is reduced along the passing direction. The angular positioning of the welding heads can be stably adjustable. However, it is also possible to implement automated dynamic matching of the angular positioning, wherein the angular positioning depends, for example, on variations in the feed speed of the splicing mating parts.

[0060] Preferably, the welding zone includes at least one static weld head, wherein the static weld head is particularly configured as a slide weld head (Schleifsonotrode).

[0061] Furthermore, preferably, the first functional element is configured with one or two shoulders in the contact area, which contact one or more welding heads in the area of ​​the welding zone. The one or more shoulders are loaded with force to position or retain the first functional element and the isolation tab in a desired cross-sectional geometry.

[0062] Typically, the isolation profile is transported longitudinally within the welding zone at a speed of about 5 m / min or higher, preferably about 10 m / min or higher. Preferably, these speeds are in the range of about 10 to about 60 m / min, and more particularly in the range of about 15 to about 40 m / min.

[0063] Preferably, the residence time of the profile body and the first functional element in the welding zone is about 100 to about 1000 milliseconds (msec), more preferably about 200 to about 800 milliseconds.

[0064] According to the method of the present invention, the welding head can operate continuously.

[0065] Preferably, at least in the contact area where the welding head rests against the first functional element, especially in the area on the shoulder constructed on the contact area if necessary, the recess of the welding head is configured as a slit or gap. Particularly preferred is that the welding head rests against two opposing shoulders constructed on the functional element. It is also possible that only a portion of the welding head rests against the contact area of ​​the functional element or a portion of the contact area.

[0066] The welding head may also have a large free space or protrusion located inside, so as to provide ample space for geometrically demanding functional areas such as hooks, arrows or T-shaped protrusions.

[0067] The width b of a slit or gap is typically about 1 to about 3 mm, simply by welding together functional areas that are simply held straight out, such as protrusions or noses. Recesses, also in the form of slits or gaps, typically have a height h of several centimeters, for example, about 1 cm or more, preferably about 1 cm to about 20 cm. The aspect ratio h / b is preferably 5 or more. In cases where the shape of the recess in the welding head differs from that of a slit or gap as described above, the width b is measured at the location of the welding head adjacent to the contact area of ​​the first functional element to calculate the aspect ratio.

[0068] In particular, in the contact area to be connected with the profile body, the functional element is configured with one or more protrusions shaped as energy direction guides, wherein the protrusions are particularly configured as melting elements.

[0069] More preferably, the functional element is provided with one or more stop elements adjacent to one or more protrusions, the one or more stop elements defining the cross-sectional geometry to be achieved when the functional element and the profile body are combined, wherein the one or more protrusions preferably also function as shoulders.

[0070] According to the present invention, the material locking connection between one or more first functional elements and the profile body can be carried out continuously, segmentally or point by point along the longitudinal direction of the isolation profile.

[0071] In a particularly preferred method according to the invention, in addition to the profile body, functional elements as continuous materials are provided, and after establishing their material-locking connection, the isolated profile is preferably cut to a predetermined length by a cutting, stamping or milling process.

[0072] Continuous material is preferably provided on rolls, reels or spools.

[0073] Alternatively, the profile body and / or functional elements may be provided in bar form prior to establishing a material-locking connection.

[0074] The present invention also relates to an insulating profile according to the invention, which can be manufactured according to the method of the invention, wherein the profile body has a substantially flat region extending along the longitudinal direction of the insulating profile.

[0075] The insulating profile according to the invention may have a profile body having through openings at predetermined, particularly regular, intervals.

[0076] In the insulating profile according to the invention, the insulating tab often has at least one edge section that includes a connecting element, wherein the connecting element is in particular in the form of a coiled head for connection with a metal profile.

[0077] The mechanical strength of the connection between the first functional element and the profile body and / or at least one edge segment should allow for simple and reliable operation of the isolation profile during transport and processing. The connection should also be durable enough to function throughout the product's lifespan; this is familiar to those skilled in the art.

[0078] Strength can be measured, for example, by a tensile test, in which a base profile of a certain length of the isolation profile (a reference length for strength in [mm]) is fixed, and a normal force or, in certain cases a tangential force is applied to the functional element, increasing the force until the component fails (break-off force in [N]).

[0079] In the preferred case of the isolation profile according to the invention, the material-locking welded connection between the profile body and the first functional element has a strength of about 2 N / mm or higher, preferably about 5 N / mm or higher, and particularly preferably about 10 N / mm or higher.

[0080] The insulating profile according to the present invention may have an insulating tab that includes a second functional element integrally formed with the profile body and, if necessary, additional functional elements.

[0081] In particular, in the case of the isolation profile according to the invention, one or more first functional elements may be selected from surface elements and / or elements that surround one or more cavities and are constructed in a flat, curved, especially partially circular, bifurcated or angled manner in cross-section, wherein one or more functional elements preferably have T-shaped, arrow-shaped or hook-shaped sections in cross-section in the longitudinal direction.

[0082] Furthermore, in the case of the insulating profile according to the invention, one or more first functional elements may form a plurality of cavities that are to be closed if required along the longitudinal direction of the insulating profile, wherein the cavities are constructed in particular sequentially.

[0083] Typically, in the case of the isolation profile according to the invention, the profile body and, if required, one or more first functional elements are made of a polymeric material, preferably based on a thermoplastic polymer selected from the following: polyamide, polyester, polyolefin, polyketone, vinyl polymer, polyether, polycarbonate, polyphenylene sulfide, or copolymers or blends of these materials.

[0084] Preferably, the polymer material of one or more first functional elements is selected such that it is compatible with the polymer material of the profile body.

[0085] Alternatively, the surface and / or core of one or more first functional elements may be partially metallized or metallized.

[0086] Therefore, it is possible, for example, to anchor the probe, which is IR-reflected by metal (e.g., made of thin aluminum sheet), onto the insulating tab without damaging the insulating features of the profile.

[0087] For specific applications, it has proven advantageous that the polymer material of the profile body and / or the first functional element is fiber-reinforced, especially glass fiber-reinforced.

[0088] One or more edge segments can be arranged in a shape that differs from the profile body. For example, these edge segments can extend substantially parallel to the plane of the profile body or can be constructed to bend relative to the plane of the profile body.

[0089] Preferably, the insulating profile according to the invention in the first variant has a profile body having a substantially flat region extending along the longitudinal direction of the insulating profile. If desired, one or more profile bodies may also be constructed generally flat.

[0090] In some preferred embodiments of the invention, the insulating profile has at least one edge section equipped with a connecting element, which may be constructed, in particular, in the form of a rolled head.

[0091] In principle, multiple insulating tabs with very different profile geometries can be used to manufacture insulating profiles according to the invention. This also includes, in particular, hollow chamber profiles. Typical shapes, sizes, and material variations of insulating profiles are available, for example, from Ensinger or other profile manufacturers. The product can be found in the standard catalog.

[0092] Direct temperature control of the welding process or the plasticized polymer material is not required within the weld area. Instead, precise and complete control of the splicing process is achieved by monitoring and adjusting the energy input to the ultrasonic welding system or to one or more welding heads. Typically, the invoked (electrical) power allows for direct inference of the weld quality, and consequently, the product quality of the insulating profile according to the invention.

[0093] If the relevant melting point is unknown, it can be determined by calorimetry. The softening temperature can usually be retrieved from the material's technical data sheet or table, or it can be determined, for example, according to the Vicat method, especially according to DIN EN ISO 306 for determining the Vicat softening temperature.

[0094] Preferably, the insulating profile according to the invention is manufactured as follows, wherein the first functional element is made of a polymer material preferably based on a thermoplastic polymer. Typically, the thermoplastic polymer forms the main component of the polymer material, but it is also possible to include a thermoplastic polymer as only a minor component in the polymer material.

[0095] Other components of the polymer material may be selected, in particular, from the following: reinforcing materials (e.g., glass fibers, carbon fibers, mineral fibers, or polymer fibers), fillers (in the form of glass powder, spheres, or hollow spheres, chalk, talc, wood flour, silicates, especially layered silicates or amorphous silicates), additives (e.g., stabilizers, lubricants and slip agents, softeners, impact modifiers, heat stabilizers and heating stabilizers, flame retardants, coupling agents, crosslinking agents), dyes (e.g., dyes or pigments), other polymers (e.g., polymer blends or copolymers), etc.

[0096] The polymer material of the functional elements and / or insulating tabs can also be fully or only partially porous. Here, closed-cell porosity is preferred.

[0097] When the mechanical load on the functional components is foreseeable during the processing of the isolation profile or when the product is used, the functional components can be sized in terms of volume and manufactured from stronger / rigider materials. Preferably, the elastic modulus of the material is about 2000 MPa or higher, and particularly preferably, the elastic modulus of the material is about 3000 MPa or higher.

[0098] In the alternative insulating profile according to the invention, one or more first functional elements are made of a metallic material, wherein the metallic material is in particular in the form of a film or sheet, and may be used in combination with functional parts made of plastic if necessary. Here, the contact area in this embodiment is also made of a second polymer material compatible with the first polymer material.

[0099] The welding of two mating parts according to the method of the present invention is performed by plasticizing the polymer material in the contact area of ​​the mating parts. The type, composition, and state of the material (e.g., water content), as well as the energy introduced, the duration (preheating time, heating time, extrusion time, holding time), and the pressure or extrusion force applied to the mating parts all affect the composition of the weld. By introducing energy from the contraction portion of the energy direction guide in the form of ultrasonic vibration and simultaneously applying extrusion force, the polymer material of the two mating parts is melted. This also melts the contraction portion of the energy direction guide, and the melt formed in the welding area avoids the extrusion force and is driven in a free lateral direction if necessary. Here, a plasticized zone is temporarily formed in the mating area, which generally no longer allows a unique attachment to one of the mating parts after the polymer material cools / solidifies.

[0100] By appropriately designing the energy direction guide, the energy input, weld quality, and especially strength, can be controlled. Therefore, it is also possible to control whether and how much molten material is expelled from the joint area, and to control the flow direction of the molten material. This can be specifically used to obtain visually appealing products, especially when the design incorporates internal, non-directly visible molten material reservoirs.

[0101] Preferably, the tip of the energy direction guide has an angle of 30° to 120°, and the usable height of the tip (h) ERG The diameter is approximately 200 μm to approximately 3 mm, preferably up to approximately 1.5 mm. However, it is also possible for the energy direction guide to be blunt or rounded, or to have a radius or a step. The use of this step enables the pre-defined "melting height" during the welding process, because the step can, for example, function as a stop for the boundary.

[0102] Ultrasonic energy can also be introduced when there is no energy direction guide in the contact area of ​​the first functional element. The orientation of the energy introduction is meaningfully selected by those skilled in the art based on the possibility that the energy should be introduced in or near the contact area of ​​the mating parts, preferably with the distance between the welding head and the mating area (or the profile body) being about 15 mm or less, particularly preferably about 6 mm or less.

[0103] The method according to the invention also enables the placement and welding of functional elements on the insulating tabs, which are themselves constructed as hollow chamber profiles. Therefore, functional areas can also be placed directly on the thinner walls of the hollow chamber profiles.

[0104] In the first embodiment, energy is preferably introduced via a static welding head, which, for example, takes the form of a sliding welding head and has a substantially rectangular contact surface. The welding head is implemented as a sliding skid or block welding head, a slotted block welding head, a knife welding head, or a double-knife welding head, and one or more splicing mating parts are then guided past the welding head in a generally permanent contact with it.

[0105] Those skilled in the art can take familiar measures to minimize wear on the welding head due to persistent and intense frictional and sliding contact with the polymer material used, and also to reduce friction itself if necessary.

[0106] The extrusion pressure is applied from the welding head through the splicing joint to the opposite stop or anvil. This anvil can be constructed as a rigid block or the like, for example, in the form of a roller, a sliding pry bar.

[0107] The positioning of two mating parts can be achieved through geometrically defined boundaries, such as guide and stop elements in the form of rollers, tracks, conveyor belts, or molds.

[0108] Compression can be divided into extrusion and holding, wherein static or variable extrusion force (F) is applied, respectively. A ) and holding force (F) H The control of the clamping process can be performed in a force control manner (by pre-setting a force F as the target, thereby obtaining the stroke or clamping depth) or a stroke control manner (by pre-setting the stroke or clamping depth, so that the system applies the required force for this).

[0109] Force F A and F H The required action time depends on various boundary conditions (material selection, geometry, welding temperature, type of force introduced, etc.). However, it is important to maintain the force F. H The holding force F should be applied for a sufficiently long time to prevent the joint from loosening. HThe effect is long enough to cause the plasticized area of ​​the splicing zone to solidify again, especially to enhance the holding force F. H The effect lasts long enough to reduce the temperature of the splicing area below the curing temperature, crystallization temperature, or glass transition temperature.

[0110] Force can be introduced into the mating parts, for example, through rollers, cylinders, punches, skids, tracks, retaining and guiding dies.

[0111] The splicing parameters, especially the extrusion pressure and holding force, as well as their respective durations, are meaningfully and quickly obtained by professionals in the field for their respective applications.

[0112] The conveying of the isolation tabs and functional components and / or the pulling out of the completed isolation profile can be carried out, especially by means of actively driven conveyors, rollers, clamps, etc.

[0113] The method according to the invention allows for multiple variations, enabling additional functional elements to be connected not only to the profile body or edge segment, but also to one or more first functional element materials in a locking manner. In particular, the insulating profile according to the invention can also consist of two or more insulating tabs, and each insulating tab can comprise two or more profile bodies.

[0114] Product performance can be well controlled through facility design and selection of method parameters, as well as the selection and matching of material and geometric design schemes (especially for functional components). Furthermore, post-processing or repackaging steps are possible to remove potentially interfering molten flash, flush-cut welded joints to length, mark isolation profiles, or apply covering / protective films or functional films. This can also occur online.

[0115] The insulating profiles manufactured according to the method of the present invention can be accurately identified. Suitable methods for analysis include microscopic examination on microscopic images or on the insulating profile itself. Thermal analysis of the splicing area is also possible. Here, what is characterized is the mass flow or melt flow within the splicing area, an indication of the mode of plasticization, an indication of the direction and type of energy input, an indication of the profile's guiding method, and an indication of the form, geometry, and composition of the splicing mating parts.

[0116] This invention particularly relates to the following embodiments:

[0117] 1. A method for manufacturing a partition profile, particularly a partition profile used in the manufacture of windows, doors, and facade elements, wherein the partition profile includes a partition tab made of a first polymer material, the partition tab including a profile body and a first functional element extending along the longitudinal direction of the partition profile, wherein the first functional element is lockedly connected to the partition tab material in a contact area.

[0118] In the first step, the profile body and the first functional element are manufactured and provided separately.

[0119] In the subsequent second step, the profile body and the first functional element are conveyed to an ultrasonic welding device along the longitudinal direction of the isolation strip to be formed. In the ultrasonic welding device, the profile body and the first functional element are connected to each other in a material-locking manner to form a welded connection. The ultrasonic welding device includes a welding area equipped with a welding head, wherein the welding head has a recess, and the functional element is guided within the recess during the formation of the welded connection.

[0120] Furthermore, during the formation of the welded connection, the profile body and the functional element are combined into a pre-given first cross-sectional geometry viewed perpendicular to the longitudinal direction, and then guided in the pre-given first cross-sectional geometry or, if necessary, a pre-given second cross-sectional geometry different from the first cross-sectional geometry viewed perpendicular to the longitudinal direction, until the plastic material of the welded connection is cured to the extent that the profile body and the first functional element are fixed in the pre-given cross-sectional geometry.

[0121] 2. The method according to embodiment 1, wherein the profile body and the first functional element are continuously or intermittently fed to the ultrasonic welding equipment.

[0122] 3. The method according to embodiment 1 or 2, wherein the profile body and / or the first functional element are provided as a continuous material or as a bar.

[0123] 4. The method according to any one of embodiments 1 to 3, wherein the profile body and functional elements are positioned relative to each other in a predetermined, changeable relative position as needed and guided in the longitudinal direction by means of a first guiding device before passing through the welding zone.

[0124] 5. The method according to any one of embodiments 1 to 4, wherein, after passing through the welding zone, the profile body and functional elements are positioned relative to each other in a pre-given, changeable relative position as needed and guided in the longitudinal direction by means of a second guiding device.

[0125] 6. The method according to any one of embodiments 1 to 5, wherein the profile body and the functional element are pressed against each other with predetermined forces as they pass through the welding zone and at an optional second guiding device after passing through the welding zone.

[0126] 7. The method according to any one of embodiments 1 to 6, wherein the first functional element is made having one or more melting elements, the one or more melting elements extending as protrusions from the surface of the contact area of ​​the first functional element, wherein the one or more protrusions preferably extend from the surface by about 3 mm or less, more preferably by about 1.5 mm or less.

[0127] 8. The method according to any one of embodiments 1 to 7, wherein the profile body and the first functional element are conveyed at an acute angle to each other with respect to the longitudinal direction, wherein the acute-angled guide extends at least over a portion of the welding area and, if necessary, over portions of the first guide device and / or the second guide device.

[0128] 9. The method according to any one of embodiments 1 to 8, wherein ultrasonic welding is performed as near-field welding, wherein the welding head has direct contact with the first functional element, and wherein, preferably, the welding head is arranged at a distance of at most about 6 mm or less from the profile body.

[0129] 10. The method according to any one of embodiments 1 to 9, wherein the welding zone has a length of about 5 cm to about 50 cm and, if necessary, has more than one welding head.

[0130] 11. The method according to any one of embodiments 1 to 10, wherein, within the welding zone, one or more welding heads occupy different angular positions relative to the profile body in the longitudinal direction, wherein the angular positions are continuously and / or gradually changed, and the distance between one or more welding heads and the surface of the isolation tab is reduced along the passing direction.

[0131] 12. The method according to any one of embodiments 1 to 11, wherein the welding zone includes at least one static welding head, wherein the static welding head is particularly configured as a sliding plate welding head.

[0132] 13. The method according to any one of embodiments 1 to 12, wherein the first functional element is configured with a shoulder in the contact area, and the shoulder contacts one or more welding heads in the area of ​​the welding zone.

[0133] 14. The method according to any one of embodiments 1 to 13, wherein the isolation profile is transported in the longitudinal direction within the welding zone at a speed of about 5 m / min or higher, preferably at a speed of about 10 m / min or higher.

[0134] 15. The method according to any one of embodiments 1 to 14, wherein the residence time of the profile body and the first functional element in the welding zone is about 100 to about 1000 milliseconds, preferably about 200 to about 800 milliseconds.

[0135] 16. The method according to any one of embodiments 1 to 15, wherein the welding head operates continuously.

[0136] 17. The method according to any one of embodiments 13 to 16, wherein the welding head is constructed with a slit-shaped or gap-shaped recess, thereby forming two parallel end regions of the welding head, which contact the contact region of the first functional element when forming a welded connection.

[0137] 18. The method according to any one of embodiments 1 to 17, wherein, in the contact area to be connected with the profile body, the functional element is configured with one or more protrusions shaped as energy direction guides, wherein the one or more protrusions are particularly configured as melting elements.

[0138] 19. The method according to embodiment 18, wherein the functional element is provided with one or more stop elements adjacent to one or more protrusions, the one or more elements defining the cross-sectional geometry to be achieved when the functional element and the profile body are combined, wherein the one or more protrusions preferably also function as shoulders.

[0139] 20. The method according to any one of embodiments 1 to 19, wherein the material locking connection between one or more first functional elements and the profile body is performed continuously, segmentally or point by point along the longitudinal direction of the isolation profile.

[0140] 21. The method according to any one of embodiments 1 to 20, wherein, in addition to the profile body, functional elements as continuous materials are provided, and after establishing their material-locking connection, the isolation profile is preferably cut to a predetermined length by a cutting, stamping or milling process.

[0141] 22. The method according to embodiment 21, wherein the continuous material is provided on a roll, drum, or reel.

[0142] 23. The method according to embodiment 21, wherein the profile body and / or functional element are provided in the form of a rod before establishing a material-locking connection.

[0143] 24. The method according to any one of embodiments 1 to 23, wherein the profile body has a substantially flat region extending along the longitudinal direction of the insulating profile.

[0144] 25. The method according to embodiment 24, wherein the profile body has through openings at predetermined, particularly regular, intervals.

[0145] 26. The method according to embodiment 24 or 25, wherein the isolation tab is constructed having at least one edge segment, the edge segment including a connecting element, wherein the connecting element is particularly in the form of a crimped head for connection with a metal profile.

[0146] 27. The method according to any one of embodiments 24 to 26, wherein the material-locking welded connection between the profile body and the first functional element has a strength of about 2 N / mm or higher, preferably about 5 N / mm or higher, and particularly preferably about 10 N / mm or higher.

[0147] 28. The method according to any one of embodiments 24 to 27, wherein the isolation tab includes a second functional element integrally constructed with the profile body and, if necessary, additional functional elements.

[0148] 29. The method according to any one of embodiments 24 to 28, wherein one or more first functional elements are selected from surface elements and / or elements that are constructed in a flat, curved, especially partially circular, bifurcated or angular manner in cross-section and surround one or more cavities, wherein one or more functional elements preferably have T-shaped, arrow-shaped or hook-shaped sections in cross-section in the longitudinal direction.

[0149] 30. The method according to any one of embodiments 24 to 29, wherein one or more first functional elements form a plurality of cavities, which are to be closed if required, along the longitudinal direction of the insulating profile, wherein the cavities are constructed in particular sequentially.

[0150] 31. The method according to any one of embodiments 24 to 30, wherein the profile body and, if required, one or more first functional elements are made of a polymeric material, preferably based on a thermoplastic polymer selected from: polyamide, polyester, polyolefin, polyketone, vinyl polymer, polyether, polycarbonate, polyphenylene sulfide, or copolymers or blends of these materials.

[0151] 32. The method according to embodiment 31, wherein the polymer material of one or more first functional elements is selected such that it is compatible with the polymer material of the profile body.

[0152] 33. The method according to any one of embodiments 24 to 32, wherein the surface and / or core of one or more first functional elements are partially metallized or metallized or equipped with metal.

[0153] 34. The method according to any one of embodiments 24 to 33, wherein the polymer material of the profile body and / or the first functional element is fiber-reinforced, particularly glass fiber-reinforced. Attached Figure Description

[0154] These and other advantages of the present invention are explained in detail below with reference to the accompanying drawings. Specifically:

[0155] Figure 1 A first embodiment of the insulating profile manufactured according to the present invention is shown;

[0156] Figure 2A and 2B Further variations of the first embodiment of the insulating profile manufactured according to the present invention are shown;

[0157] Figure 3 Further variations of the first embodiment of the insulating profile according to the present invention are shown;

[0158] Figure 4 and 5 Different exemplary variations of manufacturing the insulating profile according to the invention are shown;

[0159] Figure 6 Further variations of the insulating profile manufactured according to the present invention are shown;

[0160] Figure 7A and 7B A schematic diagram of the welding head used according to the present invention is shown;

[0161] Figure 8 A first variation of the ultrasonic welding apparatus used according to the present invention is shown;

[0162] Figures 9 to 11 Further variations of the ultrasonic welding apparatus used according to the present invention are shown;

[0163] Figure 12A and 12B The diagram shows the equipment in three-dimensional form and cross-sectional views of different sections. Figure 8 Implementation methods of ultrasonic welding equipment;

[0164] Figure 13 A schematic diagram of a method according to the invention for manufacturing an insulating profile according to the invention is shown;

[0165] Figure 14 Several variations of the functional element are shown;

[0166] Figures 15 to 17Further variations, including microscopic images of material-locking connections, are shown for the manufacture of functional elements of the insulating profile according to the present invention; and

[0167] Figure 18 A variation of a testing apparatus for insulating profiles is shown for determining the strength of functional elements spliced ​​according to the present invention. Detailed Implementation

[0168] Figure 1 A first embodiment of an insulating profile 10 manufactured according to the present invention is schematically shown, the insulating profile being based on an insulating tab 12 having a flat profile body 14. Edge sections 16, 18 configured as so-called rolled heads are connected to the profile body 14. The insulating tab 12 is made of a first polymer material.

[0169] Edge segments 16 and 18 extend along the longitudinal direction of the insulating profile 10 according to the invention and are formed transversely and spaced apart from each other on the outer edge of the profile body 14. The manufacture of such insulating tabs 12 made of polymer material can be economically achieved in the extrusion molding step with high cross-sectional geometry accuracy and high straightness without significant expense. The extrusion molding tools required for this are not particularly complex and are relatively inexpensive to obtain.

[0170] The edge sections 16, 18, configured as roll heads, are pushed into corresponding grooves in the metal profile when the insulating profile according to the invention is processed into a metal-plastic composite profile, and are shear-resistantly connected to the metal profile in the so-called roll-forming step when necessary.

[0171] Furthermore, edge sections 16, 18 may also have grooves 20 into which a so-called fusion line (not shown) can be placed. Preferably, the fusion line is held within the groove 20 by form-locking and / or force-locking. After the roll-fit connection is established, the fusion line can be activated by heating, for example during powder coating baking, to further ensure the shear-resistant connection between the insulating profile and the metal profile.

[0172] The insulating profile 10 also includes separately formed first strip-shaped functional elements 22, which are materially locked to the profile body 14 by means of an ultrasonic welding method according to the invention. In this embodiment, the first functional element 22 is made of a second polymer material, which may be the same as or different from the first polymer material. It is important for the material locking connection that these polymer materials are compatible with each other, in the case of using different polymer materials. Numerous examples of compatible polymer materials can be found, in particular, in Saechtling Kunststoff Taschenbuch, 30th edition, ISBN 978-3-446-40352-9, pages 739 and 740 (Tables 8.5 and 8.6).

[0173] In particular, the following combinations are suitable: those that are rated as “mixable or compatible” in Table 8.5 or characterized by the symbols “+” and “O” in Table 8.6.

[0174] To facilitate material locking, the first functional element 22 has a contact area 24 on its edge region. This contact area, in this embodiment, has a T-shape, resulting in shoulders 26 extending from both sides of the functional element 22. The function of these shoulders is utilized within the scope of the ultrasonic welding method described according to the invention. Figure 2A and 2B and utilization Figure 7A A more detailed explanation will follow.

[0175] If the first functional element is made of a polymer material, those skilled in the art can provide inexpensive manufacturing methods for the first functional element 22, such as extrusion molding. Similarly, the functional element can be derived from a large-area sheet of material (e.g., blown film, calendered sheet or film), which is then cut, stamped and / or shaped. The contact area can also be spliced ​​onto, for example, a flat substrate by extrusion molding.

[0176] exist Figure 2A and 2B The illustration shows a variation of the isolation profile 30 or 40 according to the invention, wherein the flat profile body 14 of the isolation tab 12 is respectively connected to the first strip functional element 32 or 42 by means of ultrasonic welding in a material locking manner according to the invention.

[0177] The first functional elements 32 and 42 of the isolation profiles 30 and 40 are respectively made separately from the isolation tab 12 or its profile body 14, and are then connected to the isolation tab 12 or its profile body 14 by means of ultrasonic welding according to the present invention.

[0178] exist Figure 2AIn one embodiment, the first functional element 32 is made of a polymer material, which is compatible with the polymer material of the profile body 14 when they are different.

[0179] The first functional element 32 has a contact area 34 on its edge region, which is designed in an L-shape and formed with a protrusion 36 that is triangular in cross-section. The protrusion 36 of the contact area 34 functions as a so-called energy direction guide in the ultrasonic welding method, and is melted (melting element) and pressed together when the materials of the functional element 32 are locked together.

[0180] Figure 2B The first functional element 42 of the isolation profile 40 may be made of a material that is not required to be compatible with the first polymer material of the isolation tab 12, and in particular, it may be made of ceramic or metal material, for example, in the form of a strip of sheet or a perforated sheet.

[0181] In order to be locked with the material of the isolation tab 12, the first functional element 42 has an L-shaped contact area 44, which has a protrusion 46 made of a second polymer material compatible with the first polymer material.

[0182] When the first functional element 42 is materially locked and connected to the profile body 14, the protrusion 46 is melted and pressed.

[0183] In ultrasonic welding, the protrusion 46, which also functions as an energy direction guide, is connected to the contact area 44 of the first functional element in a material-locking and / or shape-locking manner.

[0184] The contact areas of the first functional elements 22, 32 and 42 are connected to the material locking of the profile body 14 without the addition of auxiliary materials.

[0185] The connection between the isolation tab 12 or its profile and the first functional elements 22, 32 and 42 can be established continuously or at predetermined, especially regular intervals (point-by-point or segment-by-segment), according to the present invention.

[0186] The connection between the isolation tab 12 and the first functional elements 22, 32, and 42 typically only needs to be stable enough to reliably maintain the shape of the isolation profiles 10, 30, and 40 during transport and handling until the completion of the metal-plastic composite profile. This is because... Figure 1 and 2A The first functional elements 22, 32, and 42 shown in 2B are typically not required to absorb forces in the installed state and are used, for example, only to interrupt convective flow within the metal-plastic composite profile. Such functional elements, also referred to as protrusions, typically extend several centimeters from the surface of the insulating tab.

[0187] Figure 3 It shows the relationship with Figure 2A The functional element 32 used is an alternative variation of the first functional element.

[0188] The first functional element 52 has a slightly bent contact area 54, the tip 56 of which is configured as a protrusion that melts during ultrasonic welding and can be pressed together when forming a material-locking connection with the corresponding insulating tab.

[0189] Figure 3 The first functional element 62 has a T-shaped design within its contact area 64, wherein two protrusions 66 and 67 are configured as energy direction guides. The advantage of this type of contact area is that at least a majority of the molten material generated during ultrasonic welding can be contained within the intermediate space between the protrusions, thus creating a visually appealing welded connection between the first functional element and the associated profile. The contact surface can also be increased if desired.

[0190] Additionally, the energy input to the welding head is directed directly, and especially linearly, from the shoulder to the tip of the melting element, which provides improved efficiency in process control.

[0191] Examples of the first functional elements 72 and 82 should be determined to be sized so that, according to the invention, more complexly constructed first functional elements can also be used, wherein contact areas 74 or 84 with protrusions 76 or 86 are also provided, which are melted and pressed in ultrasonic welding to form a material-locking connection.

[0192] Figure 4 It shows the relationship with Figure 1 Compared to other possible variations of the first functional element, the isolation profile 10 is also relevant.

[0193] exist Figure 4 In a variant of the isolation profile 90, the first functional element 96, which has a semi-circular cross-section, is connected to the profile body 94 of the isolation piece 92 by means of ultrasonic welding.

[0194] exist Figure 4 In the isolation profile 100 shown in the figure, the first functional element 106, which is basically U-shaped to V-shaped in cross-section, is connected to the profile body 104 of the isolation tab 102 by means of ultrasonic welding material.

[0195] It is obvious that for the variants 90 and 100 of the first functional element, a welding head that is geometrically matched to the cross-section of the functional element must be used, so that a satisfactory welded connection can be achieved despite the expansion of the functional area of ​​the element.

[0196] Figure 5 Further variations of the isolation profiles 110, 120, and 130 manufactured according to the invention are shown, wherein the first functional elements 112, 122, and 132 according to the invention are materially locked to the profile bodies 114, 124, and 134. The first functional elements 112, 122, and 132 here have a T-shape, arrowhead shape, or thorn shape (so-called noses or short protrusions) at their respective free ends.

[0197] The profile body 134 is also bent in the edge region where the coiling head is located. The coiling heads of the isolation profiles 110, 120, and 130 are each provided with a groove (similar to...). Figure 1 (As shown in the example), these grooves are shaped to fit together to accommodate the so-called melt lines 116, 126 and 136.

[0198] Figure 6 A partition profile in the form of a facade spacer 150 is shown, having a meandering partition tab 152 with an edge section in the form of an anchoring protrusion 154 at the end of its profile body 156. The partition tab 152 is typically manufactured in one piece during an extrusion molding step and may include one or more functional elements within the scope of the invention. Figure 6 In the example, a U-shaped retaining profile 158, serving as the first functional element, is materially locked to the profile body 156. The functional element 158 ​​has a receiving groove 160 within its U-shaped cross-section, which is defined on both sides by a protrusion 162. Each protrusion 162 has a locking protrusion at its free end pointing into the groove 160.

[0199] The retaining profile 158 can, for example, accommodate and fix a sealing element, such as a sealing lip, and can be material-locked fastened to one or more positions on the profile body 156 of the isolating tab 150. Of course, the functional element (here, the retaining profile 158) can be placed not only on one side of the facade spacer 150, but also on the opposite side, and can be material-locked to the profile body 156.

[0200] Figure 7AA welding head 170, usable in the method according to the invention, is shown, having a gap or slit-shaped receiving portion, the welding head held within an ultrasonic welding apparatus (not shown) with its upper region 172. Also not shown is the necessary base (anvil) on the underside of the isolating tab 12, on which the isolating tab rests and is guided or pulled during welding. The aspect ratio of the gap or slit width b to the height h is preferably about 5 or greater. Thus, a first functional element can also be fabricated, the extension perpendicular to the surface of the isolating tab being sufficient to function as a so-called protrusion. Surprisingly, such a large aspect ratio does not significantly adversely affect the functionality of the welding head.

[0201] Following the upper region 172, the lower region 174 of the welding head is constructed with a recess 176 having a gap or slit shape. Within the recess 176, as in... Figure 7A The first functional element, which is shown as functional element 22, is contained within the recess 176, except for the contact area 24 of the functional element.

[0202] The lower region 174 of the welding head 170 ends on the upper side of the contact region 24 of the first functional element 22 with the wall elements 178, 179 that define the recess 176. The positioning of the welding head 170 is carried out such that the energy direction guide 28 of the first functional element 22 contacts the isolation tab 12 body in the section of the welding equipment shown here.

[0203] exist Figure 7B Details of the welding head 170 are shown, wherein the first functional element 180 is completely accommodated within the recess 176 except for the contact area 182 of the first functional element. A variant of the welding head 190 with a recess 192 is also shown, the recess being larger than the recess 176, and thus also accommodating first functional elements 194, 196, which have different and unfolded geometries spaced apart from their contact areas 198 or 199 compared to the first functional element 180.

[0204] exist Figure 8 The diagram schematically illustrates a first variant 200 of an apparatus for performing a method for manufacturing an insulating profile according to the invention, the apparatus having a first guide zone 202 in which separately manufactured and interconnected elements of the insulating profile (i.e., on the one hand, an insulating tab 12 and on the other hand, a first functional element 22) are conveyed from the first guide device (not shown) in a pre-given orientation to a welding zone 204 arranged thereafter and an ultrasonic welding device disposed within the welding zone.

[0205] Following welding area 204 is holding area 206, which carries out the assembled and material-locked components from welding area 204 as manufactured isolation profile 10. A second guide device (not shown) is placed in holding area 206 for this purpose.

[0206] The weld head forming the welding zone 204 is in Figure 8 The middle part is arranged at an acute angle α of less than about 5°, especially less than about 3°, relative to the isolation tab 12, so that for the free end of the welding head where the recess (in which the first functional element is guided) is arranged, it gets closer and closer to the surface of the isolation tab 12 as the degree of melting of the protrusion on the contact area 24 of the first functional element 22, which acts as an energy input element, increases. This is in Figure 8 The two additional cross-sectional views (a) and (b) illustrate this schematically. Based on this geometry, the material of the energy input element 28 is continuously melted and simultaneously compressed such that the cavity between the shoulders 26 is filled with molten extrusion and forms a compressed region, which in Figure 8 The details in (b) are marked with reference numeral 29.

[0207] Figure 9 A second variation 220 of the apparatus for performing the method for manufacturing an insulating profile according to the invention is shown. Here, a first guide region 222 (not shown) of a first guide device is provided, through which the insulating tab 12 and the first functional element 22 are synchronously, preferably continuously, conveyed to a welding region 224 containing a welding head.

[0208] The welding head 224 is constructed parallel to the transport path and orientation of the isolation tab 12; however, the lower side of the welding head 224 extends at an acute angle α relative to the surface of the isolation tab 12, thereby causing the first functional element 22 and its contact area 24 to geometrically approach the surface of the isolation tab 12 when passing through the welding area 224. Viewed in cross-section, this also results in... Figure 8 (a) and Figure 8 The same shape as in (b).

[0209] Immediately following the welding zone 224 is a holding zone 226 having a second guiding device (not shown) that holds the elements of the isolation tab 12 and the first functional element 22, which are mutually material-locked together, in a desired cross-sectional geometry, so that the formed weld can be cooled and ultimately an operable isolation profile 10 with the desired geometry is obtained.

[0210] exist Figure 10The diagram shows a third variation 240 of the apparatus for performing the method for manufacturing an insulating profile according to the invention, wherein a first guiding device (not shown) is used in the first guiding area 242 to convey a first functional element having a predetermined geometry relative to the insulating tab 12 to the welding area 244 (welding head).

[0211] Here, the welding head 244 is also horizontally oriented, but it has a modified geometry on the lower side, which causes the first functional element to approach the isolation tab 12 when passing through the welding area 244, as corresponding to Figure 8 (a) and Figure 8 As shown in the two illustrations in (b). In this variant, a second holding device (not shown) is also provided in the holding area 246 after the welding area 244. The second holding device guides the combination of the isolation tab 12 and the first functional element, which are connected in a locking manner, as the isolation profile 10, and fixes it in the corresponding geometry until the weld cools.

[0212] exist Figure 11 The diagram shows a fourth variation of the apparatus 260 for manufacturing the insulating profile according to the invention, wherein the insulating tab 12 and the first functional element are together delivered to the welding area 264 in a pre-given geometric arrangement.

[0213] In this embodiment of the apparatus 260 for performing the method according to the invention, the welding area 264 is divided into two sections formed by two welding heads 265a and 265b.

[0214] The welding head 265a is arranged substantially horizontally, that is, largely parallel to the passage direction of the isolation tab 12 and the first functional element, and ensures the melting of the energy input element of the first functional element through energy input. In the second stage of the molten zone 264, the welding head 265b, arranged at an angle α relative to the transport direction of the isolation tab 12, causes the contact area of ​​the first functional element to be positioned relative to the surface of the isolation tab 12, thereby achieving the desired cross-sectional geometry of the isolation profile to be manufactured during the transition from the welding zone 264 to the second guide device (not shown) in the holding zone 266. The arrangement of the isolation tab 12 and the first functional element 22 before and after the welding process corresponds to the arrangement of the isolation tab 12 and the first functional element 22 in the welding zone 264. Figure 8 The two illustrations in (a) and (b).

[0215] Even in combination Figures 8 to 11In describing the method according to the invention, the starting point is always to ensure that the cross-sectional geometry achieved in the welding zones 204, 224, 244, and 264 remains unchanged until the weld is sufficiently cooled and hardened or solidified, while the second guiding devices in zones 206, 226, 246, and 266 respectively ensure that the cross-sectional geometry remains unchanged until the weld is sufficiently cooled and hardened or solidified. It is also entirely possible to configure the method to produce a change in cross-sectional geometry within the second guiding devices, so that the first functional element 22 no longer behaves as before. Figure 8 (b) shows that the weld does not extend perpendicularly to the isolation tab 12, but is instead guided at a different angle, thereby allowing the weld to solidify in a suitable shape and thus achieving [the desired effect]. Figure 8 (b) depicts the shapes of different isolation tabs 12 and the first functional element 22.

[0216] Figure 12A The perspective view shows an apparatus 300 for performing the method for manufacturing an insulating profile according to the present invention. The first and second guiding devices for the guiding and retaining areas are also clearly explained here.

[0217] The device includes a first guide device 302 in the form of a mold, in which the isolation tab 12 and the first functional element 22, which are conveyed to the device 300, are held in a pre-given geometry relative to each other and are transported toward the subsequent welding area 304. The relative arrangement of the isolation tab 12 with respect to the first functional element 22 is shown in cross-sectional views (a) and (b) at this stage, where it can also be seen that a slit-like recess 310 is provided in the first guide device 302, within which the first functional element 22 is guided.

[0218] Preferably, in this recess 310 of the first guiding device 302, most of the contact area 24 of the first functional element 22 is also accommodated by the recess 310, and the contact area 24 gradually approaches the upper surface of the isolation tab 12.

[0219] In the molten zone 304 of the welding head in regions (c) to (d) following the first guiding device 302, the first functional element 22 is guided within the recess 312 of the welding head 304. However, the difference is that here, the contact area 24 of the first functional element 22 is located outside the body of the welding head 304, so that the contact area 24 can approach the surface of the isolation tab 12 unimpeded while the energy direction guide is pressed and a continuous ultrasonic welding energy input is made, as shown at the end of the welding zone 304 in the cross-sectional view (d).

[0220] Following the welding zone 304, the isolation tab 12, which is material-locked to the first functional element 22, is guided within the second guide device 306 to the desired final cross-sectional geometry. The guide device 306, also having a recess 314, substantially accommodates the first functional element 22.

[0221] The main body of the guiding device 306, as shown herein, can be a rigid mold, but this body can also be implemented in other ways, such as in the form of a pressing roller.

[0222] Finally, after leaving the second mobile device 306, the isolation profile 10 is received by the transport device 308 and pulled out of the device.

[0223] The handover from the guide zone to the welding zone in the areas (b) to (c) of the splicing mating parts, and the handover from the welding zone to the holding zone in the areas (d) to (e) of the splicing mating parts, can be carried out without special guides over a short stroke of a few millimeters or centimeters, i.e., unguided, for example, through an air gap.

[0224] exist Figure 13 The process steps are shown again in the flowchart, where the terms splicing mat 1 and splicing mat 2 mean the isolation patch 12 and the first functional element 22.

[0225] Typical parameters for performing the method according to the invention can be summarized as follows:

[0226] The pass-through or pull-out speed of the manufactured isolation profile 10 is typically in the range of about 10 m / min or higher, of which significantly higher values ​​can also be achieved, such as about 15 m / min or higher, or about 30 m / min or higher.

[0227] At the aforementioned pull-out speeds, the dwell time of a given profile portion within the weld zone is highly dependent on the material and geometry, and typically ranges from approximately 0.2 to approximately 0.6 seconds. If a higher energy input is required, it can be operated at a slightly lower pull-out speed (resulting in a longer dwell time), thus allowing for a higher energy input (relative to the weld length) as it passes through the weld zone. At significantly higher pull-out speeds, it is generally necessary to extend the weld zone, for example by joining additional weld heads, but this can typically be achieved simply in the method according to the invention, for example, from... Figure 12A As can be seen in the perspective diagram.

[0228] The merging of the isolation tab and the first functional element is preferably achieved, on the one hand, by feeding and on the other hand, by geometrically bringing the two components, the isolation tab 12 and the first functional element 22, into close proximity. The force used to press the two components against each other is determined by material properties, a pre-defined pull-out speed, the height of the molten element, and the geometric profile of the welding head along the profile's running direction. So-called "stroke-controlled welding" is achieved through the pre-defined positioning of the static welding head and its geometric profile along the profile's running direction. According to the invention, this is preferred over force-controlled welding because tolerances can therefore be kept within tighter limits.

[0229] The extrusion duration, that is, the time period during which the interlocking profile is guided through the second guiding device and stabilized to allow the material to be locked together, is designed based on the time required for the weld to solidify and for the product itself to be operable. Typically, a duration of about 0.2 to about 1 second is sufficient because plasticization is very localized and thus the heat to be dissipated can be kept relatively low.

[0230] In the following Figures 14 to 17 The contact area of ​​the first functional element under various different shapes is shown and discussed again.

[0231] Figure 14 The contact area 182 of the first functional element 180 is shown at the first location (simplified diagram (a)), as in Figure 7B This has already been discussed. In Figure 14 The simplified diagram (b) shows the first functional element 340, wherein the contact area 342 is configured with two protruding protrusions 344, 346 that function as energy direction guides and define a cavity 348 therebetween, in which at least a portion of the molten material of the energy direction guides 344, 346 can be accommodated during the welding process.

[0232] exist Figure 14 The simplified diagram (c) shows a first functional element 360 with a contact area 362, and four protrusions 364 in triangular cross-section are constructed on the free end of the contact area. These protrusions function as energy direction guides and form three cavities therebetween, in which the molten material of the contact area 362 can be contained during the welding process.

[0233] exist Figure 14 In the simplified diagram (d), a first functional element 22 is shown for comparison. This first functional element has a contact area 24 and an energy direction guide 28 with a triangular protrusion arranged within the contact area. Additionally, the contact area 24 (and...) Figure 14The simplified diagram (a) of the implementation has two additional protrusions 27, which respectively form stops and define the relative positioning of the isolation profile or the cross-sectional geometry to be achieved during the formation of the welded connection.

[0234] Here, a cavity volume is provided below the shoulder 26 and on both sides of the energy direction guide 28, which can accommodate the molten material of the energy direction guide during the ultrasonic welding process, thereby enabling a visually aesthetically pleasing connection between the first functional element 22 and its corresponding isolation tab. The cavity volume is limited on both sides by the stop element 27.

[0235] exist Figure 14 The simplified diagram (e) shows an alternative to the first functional element 400, wherein the contact area 402 is equipped with a protrusion 404 in a triangular cross-section as an energy direction guide. The cross-section of this energy direction guide 404 is smaller than... Figure 14 The simplified diagram (d) shows the cross-section of the energy direction guide 28, or is also smaller than... Figure 14 The simplified diagram (b) shows the cross-section of the energy direction guides 344 and 346.

[0236] Here, since the volume fraction that may be compressed during the welding process is relatively low, it is typically unnecessary to have a hollow volume to contain the molten material. Instead, the molten material is distributed substantially uniformly on the underside of the contact area 402 of the first functional element 400. Here, the volume of the molten material formed is small, but the energy requirement for plasticizing this volume is also reduced, and thus the welding process can be carried out at a higher feed rate.

[0237] In a similar way, Figure 14 In the simplified diagram (f), in the case of the first functional element 410 and its contact area 412 shown here, the volume of the energy direction guide 414 is designed to be lower due to its smaller cross-sectional dimensions, and therefore preventive measures are taken to prevent the molten material of the energy direction guide 414 from escaping laterally from the contact area 412. Furthermore, the energy direction guide 414 is arranged on the tapered surface structure 416 of the contact area 412, such that after the energy direction guide melts, a volume is left on both sides of the energy direction guide 414 between the contact area 412 and the surface of the insulating tab (not shown here), which can readily accommodate the molten material of the energy direction guide 414.

[0238] exist Figure 14The simplified diagram (g) shows a slightly different variation in conjunction with the first functional element 420, wherein the contact area 422 is equipped with a tapered structure 426 in addition to the energy direction guide 424. The cross-section of the energy direction guide 424 is also kept smaller than in the simplified diagram (f), thereby ensuring with greater reliability that the volume of the formed molten material is retained between the contact area 422 and the surface of the insulating tab (not shown). The height of the tapered structure 426 here functions as a stop element.

[0239] In the case of the geometry of the contact areas 412 and 422 shown in Figures (f) and (g), it is also suggested that the tapered protrusions 416, 426 be designed such that the geometry generated when passing through the welding area immediately after the plasticization of the splicing area is changed again in a hot, plasticized state in a later step (e.g., in a correspondingly constructed second guide device), so that the inclination of the first functional elements 410, 420 relative to the surface of the isolation tab (not shown here) deviates from the vertical.

[0240] Figure 15 Several variations of the contact area of ​​the first functional element are also shown, based on the premise that... Figure 14 A variation of the contact area 342 is shown in the simplified diagram (b). In this type of contact area, the contact surface for the welding head formed by the shoulder 350 is arranged substantially perpendicular to the force introduction plane, and reliable and defined guidance of the first functional element within the molten zone is achieved.

[0241] exist Figure 15 In a variant of the simplified diagram (b), the first functional element 440 has a contact area 442, wherein a shoulder forms a contact surface for the welding head, the contact surface being at an obtuse angle to the force-introducing plane. This design of the contact area stabilizes the geometry of the contact area, especially when high forces are introduced via the welding head, and requires a matching welding head so that the area in contact with the shoulder and introducing force into the contact area maintains its geometry to a sufficient extent during welding, and ensures targeted force introduction.

[0242] The latter problem is addressed in particular by the design of the first functional element 460, which has a contact area 462 with an acute angle relative to the force-introducing plane formed by the shoulder 464. This provides centering of the welding tip in contact with the contact surface, thus allowing for greater structural flexibility in the design of the welding tip, while still enabling reliable, purposeful, and defined force introduction.

[0243] The design of the welding head for optimal force introduction can be achieved by ensuring that one or more angles of the shoulders(s) of the functional elements are correspondingly reflected in the shape of the welding head. However, it is important to note, in general, that the welding head has sufficiently good vibration characteristics.

[0244] In another variation of the contact area of ​​the first functional element, the contact area is constructed as a protrusion of an energy direction guide, and its geometry is changed, and compared with the embodiment of the first functional element 340 (simplified figure (a)).

[0245] exist Figure 15 A variant of the first functional element 480 shown in the simplified diagram (d) has two protrusions 484 and 486 within its contact area 482, their tips pointing slightly opposite each other. Sufficient volume 488 is provided between the protrusions 484 and 486 to accommodate the molten material during the ultrasonic welding process, and the geometry of the protrusions further deflects the molten material toward the volume 488. Thus, relative to... Figure 15 A variation of the simplified diagram (a) further reduces the tendency for the melt to undesirably run laterally into the contact area.

[0246] According to Figure 15 In the design of the first functional element 500 in the simplified diagram (e), a stronger effect is achieved in controlling the flow of the melt in the direction of a predetermined volume between the protrusions. In this case of the first functional element 500, the protrusions 504 and 506 of the contact area 502 arch relative to each other and partially surround the volume 508 between the protrusions.

[0247] Combination Figure 16A and 16B This section discusses other aspects of the design scheme for the contact area of ​​the first functional element. (Corresponding to...) Figure 14 Compared to embodiment (a), the embodiments shown in diagrams (b), (c), and (d) are respectively equipped with a volume in the contact area for containing molten material, which is preferably sized to be about 5 to about 50% larger than the volume of molten material that accumulates and is to be expelled during the welding process. More preferably, the volume is about 5 to about 30% larger, for example, 20% larger.

[0248] exist Figure 16AThe simplified diagram (b) shows a first functional element 520 having a T-shaped contact area 522, wherein a centrally located protrusion 524 is configured as an energy direction guide with a substantially triangular cross-section. Within the contact area, volumes 526 and 528 (shaded) are provided on both sides of the protrusion 524, which can accommodate the portion of polymer material to be expelled from the protrusion 524 during ultrasonic welding.

[0249] exist Figure 16A In embodiment (c), the first functional element 540 has a T-shaped contact area 542, wherein the individual protrusion 544 also functions as an energy direction guide. Recesses 546 and 548 are provided on both sides of the protrusion 544 to accommodate the volume that appears and is to be expelled during ultrasonic welding. The volumes 546 and 548 are significantly larger than the volumes 526 and 528 in the embodiment shown in Figure (b), however, with the same contact area specifications, when the same polymer material is used in the T-shaped structure, a significantly lower wall thickness is retained, resulting in correspondingly lower strength.

[0250] For further comparison, it is shown in simplified diagram (d). Figure 15 (a) The first functional element 340, wherein a volume 348 for containing the molten material is arranged between parallel extending protrusions 344 and 346. The volume 348 is defined to be slightly smaller than that of the embodiment in schematic (b), but the mechanical stability of the contact area 342 of the first functional element 340 is higher than that in the first functional element 520. Because there is no proven advantageous stop boundary here, as is also the case in variant 180, the resulting volume of molten material will depend on the melting height. For this reason, it is meaningful in this case and in similar arrangements to perform precise control of the melting height, for example, by process control of the welding process in a stroke control manner.

[0251] at last, Figure 16B A particularly preferred embodiment of the first functional element 560 and its illustration are shown in the microscopic images. The microscopic images reveal how the molten polymer material of the protrusions 564 and 566 is contained within a volume 568, which is defined to be larger than the desired molten material volume. Additionally, in addition to the protrusions 564 and 566, a groove-like recess 570 is provided, which can accommodate any possible laterally displaced molten material volume and ensures a visually optimal result for obtaining a material-locked connection between the first functional element and the associated insulating tab.

[0252] The groove-shaped recess 570 is defined on the outer side of the contact area 562 by rib-shaped protrusions 576, which respectively form stop elements, thereby allowing the first functional element 560 to be brought into a defined positioning and orientation relative to the surface of the isolation tab (not shown). Furthermore, this avoids unintended excessive deformation of the contact area 562.

[0253] In the case of this first functional element 560, in addition to the high mechanical stability of the contact area 562 including its shoulders 572, 574, a relatively large volume is provided for accommodating the melt, and additionally, precautions are taken to prevent the molten portion of the polymer material of the protrusions 564, 566 from or from visibly leaving laterally.

[0254] The concept for designing the contact area of ​​the first functional element is in Figure 17 The diagram is used again to illustrate this.

[0255] For reference, the first functional element 180 and its contact area 182 are inserted again as a simplified diagram (c).

[0256] In variations (a) and (b) of the first functional elements 580 and 600, in the T-shaped contact areas 582 and 602 having protrusions 584 and 604, volumes 586, 588 or 606, 608 of comparable size are provided on both sides of the protrusions 584 and 604. In the embodiment of the first functional element 600, the weakening of the shoulder 610 is due to the larger height h of this portion of the contact area 602. 肩部 Therefore, the shoulder of the contact area 602 of the first functional element 600 can be loaded in a similar manner to the shoulder of the contact area 182 of the first functional element 180. In the case of the first functional element 580, it must be noted that only a low force should be applied in the area of ​​the shoulder 590 to avoid deformation or even damage to the contact area 582. Figure 17 In the implementation of the first functional element 580, 600 depicted in the simplified diagrams (a) and (b), the lateral protrusion that limits the volume of the molten material also functions as a stop element.

[0257] Within the scope of the description of various embodiments of the insulating profile according to the invention, it has been demonstrated that the contact area formed when the insulating tab and the first functional element are connected by material locking can be constructed in different sizes depending on the application or purpose of the insulating profile according to the invention. However, it is important that the mechanical strength of the connection between the insulating tab and the first functional element is sufficient to allow the insulating profile according to the invention to be reliably operated and processed.

[0258] Should be in Figure 18 The detailed tests described within the scope are suitable for characterizing the strength of the joint and the load-bearing capacity of the associated machinery.

[0259] Figure 18 The test equipment 800 is shown, which can be used on a conventional general-purpose testing machine for determining the tensile bearing limit of a component.

[0260] The exemplary testing device 800 is designed for simple profiles with vertically extending protrusions; in this case, a tensile force is applied perpendicularly to the profile body during testing. However, it is also possible to design the testing device for other profile geometries, and to consider other directions of force application if necessary, provided it is appropriate, in order to obtain conclusions regarding the quality of the joint area and the connection of the joint mating parts.

[0261] The testing device 800 includes an upper test body receiving portion 802 and a lower test body receiving portion 804. The upper test body receiving portion 802 has a test body support 806 divided into two parts. An isolation profile 10 according to the invention (e.g., a carefully cut isolation profile for the test body, with a length of 20mm to 50mm) can rest against the test body support with its isolation tab 12, wherein the first functional element 22 of the isolation profile can pass through the gap between the two parts of the test body support 806. The illustration of the isolation profile 10 is shown in... Figure 18 The text is slightly simplified and not all details are shown; the details are in... Figure 1 As can be seen in the text.

[0262] The lower test body receiving portion 804 includes a pair of clamps 808, between which a section of the first functional element 22 can be clamped.

[0263] During the tensile test, a force is applied to the splice area 28 of the insulating profile 10 in the directions of arrows K1 and K2. This force is continuously increased until the first functional element is torn from the insulating tab 12. The parameters of the tensile test can be matched to obtain convincing results corresponding to the material; typically, this tensile test is performed at a speed of 1 mm / min, 5 mm / min, or 10 mm / min. The known force until the profile body fails is then normalized according to the length of the sample body of the insulating profile. It is essential to ensure that the splice area to be examined is fully and loaded in a meaningful direction, such as a normal force, during the measurement. The insulating profile according to the invention then has a strength of about 2 N / mm or higher, preferably about 5 N / mm or higher, and particularly preferably about 10 N / mm.

[0264] In many embodiments of the insulating profile according to the present invention, a flat, slatted protrusion is used as the first functional element. Although this type of first functional element is used in various ways, it can be replaced by a significantly more complexly structured first functional element when needed.

[0265] Therefore, the profile body of the insulating tab can be arbitrarily complex. Many profile geometries known to date from the prior art, especially commercially available profiles, can be used as a basis to equip additional functional elements according to the method of the invention.

Claims

1. A method for manufacturing an insulating profile, wherein, The insulation profile comprises an insulation web made of a first polymer material, which comprises a profile body and a first functional element, which extend in the longitudinal direction of the insulation profile, wherein the first functional element is connected in a material-locking manner with the insulation web material in a contact region, wherein in a first step the profile body and the first functional element are respectively separately produced and provided, wherein in a subsequent second step the profile body and the first functional element are fed to an ultrasonic welding device in the longitudinal direction of the insulation web to be formed, in which the profile body and the first functional element are connected to one another in a material-locking manner in the course of a welded connection, wherein the ultrasonic welding device comprises a welding zone equipped with a welding head, wherein the welding head has a recess in which the first functional element is guided during the course of the welded connection, and wherein during the course of the welded connection the profile body and the first functional element are combined into a predefined first cross-sectional geometry viewed perpendicularly to the longitudinal direction and then guided in the predefined first cross-sectional geometry or in a predefined second cross-sectional geometry viewed perpendicularly to the longitudinal direction which differs from the first cross-sectional geometry until the plastic material of the welded connection has cured to such an extent that the profile body and the first functional element are fixed in the predefined cross-sectional geometry.

2. The method of claim 1, wherein, The profile body and / or the first functional element are provided as a continuous material or as a rod.

3. The method of claim 1, wherein, The first functional element is produced with one or more melting elements which extend as protrusions away from the surface of the contact region of the first functional element.

4. The method of claim 1, wherein, The ultrasonic welding is performed as near-field welding, wherein the welding head has direct contact with the first functional element.

5. The method of claim 1, wherein, The welding zone has a length of 5 cm to 50 cm.

6. The method of claim 1, wherein, In the welding zone one or more welding heads are positioned at different angular positions with respect to the profile body with reference to the longitudinal direction, wherein the angular positions change continuously or stepwise and thereby the spacing of the one or more welding heads from the surface of the insulation web is reduced in the through direction.

7. The method of claim 1, wherein, The welding zone comprises at least one static welding head.

8. The method of claim 1, wherein, The first functional element is configured with a shoulder in the contact region, which comes into contact with one or more welding heads in the region of the welding zone.

9. The method of claim 1, wherein, The insulation profile is conveyed in the longitudinal direction in the welding zone at a speed of 5 m / min or more.

10. The method of claim 8, wherein, The welding head is configured with a slit-like recess, so that two end regions of the welding head arranged in parallel are formed, which come into contact with the contact region of the first functional element in the course of the welded connection.

11. The method of claim 1, wherein, In the contact region to be connected with the profile body, the first functional element is configured with one or more protrusions shaped as energy direction guides.

12. The method of claim 11, wherein, The first functional element is provided with one or more stop elements adjacent to the one or more protrusions, which define the cross-sectional geometry to be achieved when the functional element and the profile body are joined.

13. The method of claim 1, wherein, The material-locked connection between the one or more first functional elements and the profile body is continuous, section-wise or point-wise in the longitudinal direction of the insulating profile.

14. The method of claim 1, wherein, The insulating profile is an insulating profile for the production of window elements and door elements.

15. The method of claim 1, wherein, The first functional element is produced with one or more melting elements, which extend away from the surface of the contact area of the first functional element as protrusions, wherein the one or more protrusions extend away from the surface by 3 mm or less.

16. The method of claim 1, wherein, The first functional element is produced with one or more melting elements, which extend away from the surface of the contact area of the first functional element as protrusions, wherein the one or more protrusions extend away from the surface by 1.5 mm or less.

17. The method of claim 1, wherein, The ultrasonic welding is carried out as near-field welding, wherein the welding head has direct contact with the first functional element, and wherein the welding head is arranged at a distance of at most 6 mm or less from the profile body.

18. The method of claim 1, wherein, The welding zone has a length of 5 cm to 50 cm and has more than one welding head.

19. The method of claim 1, wherein, The welding zone comprises at least one static welding head, wherein the static welding head is configured as a slide-on welding head.

20. The method of claim 1, wherein, The insulating profile is transported in the longitudinal direction within the welding zone at a speed of 10 m / min or more.

21. The method of claim 1, wherein, In the contact area to be connected to the profile body, the first functional element is configured with one or more protrusions shaped as energy direction guides, wherein the one or more protrusions are configured as melting elements.

22. The method of claim 11, wherein, The first functional element is provided with one or more stop elements adjacent to the one or more protrusions, which define the cross-sectional geometry to be achieved when the first functional element and the profile body are joined, wherein the one or more protrusions are configured as shoulders.

23. The method of claim 8, wherein, The welding head is configured with a gap-like recess, so that two end regions of the welding head arranged in parallel are formed, which contact the contact area of the first functional element when the welded connection is formed.

24. The method of claim 1, wherein, The insulating profile is an insulating profile for the production of facade elements.

25. A spacer profile manufactured according to the method of claim 1, wherein, The profile body has a region which is essentially flat configured extending in the longitudinal direction of the insulating profile.

26. The spacer profile according to claim 25, wherein The material-locked welded connection between the profile body and the first functional element has a strength of 2 N / mm or more.

27. The spacer profile according to claim 25, wherein The one or more first functional elements are selected from the group consisting of flat, curved, bifurcated or angled surface elements from the cross section and / or elements which enclose one or more cavities.

28. The spacer profile according to claim 25, wherein The one or more first functional elements form a plurality of cavities in the longitudinal direction.

29. The spacer profile according to claim 25, wherein The profile body and the one or more first functional elements are produced from a weldable polymer material.

30. The spacer profile according to claim 25, wherein, The surface and / or the core of the one or more first functional elements is partially metal-coated or metalized or equipped with metal.

31. The spacer profile according to claim 25, wherein The polymer material of the profile body and / or of the one or more first functional elements is fiber-reinforced.

32. The spacer profile according to claim 25, wherein The materially bonded welded connection between the profile body and the first functional element has a strength of 5 N / mm or more.

33. The spacer profile according to claim 25, wherein The materially bonded welded connection between the profile body and the first functional element has a strength of 10 N / mm or more.

34. The spacer profile according to claim 27, wherein The curved configuration is a partial circular configuration.

35. The spacer profile according to claim 27, wherein The one or more first functional elements have a segment that is T-shaped, arrow-shaped or hook-shaped in a cross section in the longitudinal direction.

36. The spacer profile according to claim 25, wherein The one or more first functional elements form a plurality of cavities in the longitudinal direction, which are closed cavities.

37. The spacer profile according to claim 25, wherein The one or more first functional elements form a plurality of cavities in the longitudinal direction, wherein the cavities are configured in succession.

38. The spacer profile of claim 25, wherein, The profile body and the one or more first functional elements are made of a weldable polymer material, which is based on a thermoplastic polymer selected from the group consisting of: polyamide, polyester, polyolefin, polyketone, polyether, polyphenylene sulfide or copolymers or blends of these materials.

39. The spacer profile of claim 25, wherein, The polymer material of the profile body and / or of the one or more first functional elements is glass fiber-reinforced.

40. The spacer profile of claim 25, wherein, The profile body and the one or more first functional elements are made of a weldable polymer material, which is based on a thermoplastic polymer: polycarbonate.

41. The spacer profile of claim 25, wherein, The profile body and the one or more first functional elements are made of a weldable polymer material, which is based on a thermoplastic polymer: ethylene-based polymer.

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