Method for producing an extruded composite profile and composite profile

Abstract

The present invention relates to a method for producing an extruded composite profile (1, 1'), in which an aluminum profile is fed to an extrusion device and then co-extrusion is carried out by adding an aluminum alloy during extrusion to produce an extruded composite profile with sections having a different alloy composition. Alternatively, two aluminum profiles can be produced from a different aluminum alloy and then joined together using a thermal joining process. This allows the material properties of the composite profile to be optimally designed for the respective application.

Description

[0001] The present invention relates to a method for producing an extruded composite profile and a composite profile with at least two integrally formed sections made of different aluminum alloys.

[0002] EP 3 354 835 B1 discloses a composite profile for facades, doors, or windows, comprising a first aluminum profile and a second aluminum profile, at least one insulating plastic profile, and a third aluminum alloy profile. The third profile is designed with higher compressive strength and flexural strength than the second aluminum profile, and the second and third aluminum profiles are joined together by forming. This allows the composite profile to exhibit optimized material properties for thermal insulation and compressive strength for the respective application. However, the production of the individual profiles and their subsequent joining to form a composite profile through a forming process is comparatively complex.

[0003] The object of the present invention is therefore to create a method for producing an extruded composite profile that allows for optimized adaptation of the material properties using simple means. Furthermore, a corresponding composite profile is to be provided.

[0004] This object is achieved by a method having the features of claim 1 and a method having the features of claim 6. A corresponding composite profile is specified in claim 9.

[0005] According to a first method according to the invention for producing an extruded composite profile, an aluminum profile is fed to an extrusion device to add an aluminum alloy during extrusion for co-extrusion, and then an extruded composite profile is produced with sections having different alloy compositions. Thus, an optimized adaptation of the material properties of the composite profile can be achieved via co-extrusion, with the sections differing, in particular, with regard to compressive strength and flexural strength.

[0006] For the purposes of the application, the term "aluminium" shall include both aluminium as a pure substance and aluminium alloys which contain further additives in addition to aluminium, for example copper, magnesium, lead, manganese, silicon or other ingredients.

[0007] Through co-extrusion, the extruded composite profile preferably features integrally formed sections made of different aluminum alloys, each with different material properties. The individual sections can be separated from each other for appropriate material testing. This allows the different material properties to be tested to optimally adapt the resulting composite profile to the specific application.

[0008] When adding the aluminum alloy, the aluminum profile can be partially coated with an aluminum alloy. Preferably, the aluminum profile is completely coated with an aluminum alloy, whereby the added aluminum alloy can be positioned on either an outer or inner side of the aluminum profile.

[0009] According to a second method according to the invention for producing an extruded composite profile, a first aluminum profile is extruded from a first aluminum alloy, and a second aluminum profile is extruded from a second aluminum alloy that is different from the first aluminum alloy. In a further step, the first aluminum profile is then joined to the second aluminum profile using a thermal joining process, forming a one-piece composite profile. As a result, the composite profile produced in this way can comprise sections made of different aluminum alloys that are optimally adapted to the expected mechanical loads.

[0010] Preferably, the first aluminum profile is welded to the second aluminum profile. Welding can be performed, for example, using laser welding, so that a corresponding joint can be created reliably.

[0011] The composite profile produced in this way can be joined to at least one plastic insulating strip by forming. This allows the composite profile to also be provided with high thermal insulation. Preferably, the at least one insulating strip is joined to another aluminum profile on opposite sides, in particular by forming, so that the central insulating strip is connected to at least one aluminum profile on opposite sides.

[0012] The composite profile according to the invention comprises at least two integrally formed sections made of different aluminum alloys, which are connected to another aluminum profile via at least one plastic insulating web. The integrally formed sections made of different aluminum alloys can be joined together either by co-extrusion or by a thermal joining process. Such a composite profile is used in particular for the production of a frame for windows, doors, and / or a facade.

[0013] Aluminum alloys that can be used include, for example, aluminum alloys according to DIN EN-573-3W IN AW-6063, EN AW 7003, EN AW-6005 A, IN AW-60A2, and / or IN AW-6106.

[0014] The invention will be explained in more detail below using several exemplary embodiments with reference to the accompanying drawings. They show: Figures 1A and 1B show two views of a composite profile according to the invention to explain a first manufacturing method; Figures 2 and 3 show two views of a modified composite profile to explain a modified manufacturing method; Figure 4 shows a perspective view of a frame in a corner area with composite profiles according to the invention, and Figure 5 shows a sectional view through a frame with composite profiles according to the invention.

[0015] In the Figures 1A and 1Ba composite profile 1 is shown which comprises an inner first aluminum profile 2 which is completely encased in a section formed by a second aluminum profile 3 and covered with a different aluminum alloy. To produce the composite profile 1, the aluminum profile 2 is first extruded, and then this aluminum profile is fed to an extrusion device in order to add another aluminum alloy during extrusion for co-extrusion. The additional aluminum alloy can be added, for example, in powder or granular form, in order to then encase the aluminum profile 2 with a section of the modified aluminum alloy. This changes the material properties of the aluminum profile 2, whereby the material properties can be changed by appropriate additives, for example by increasing the proportion of copper, magnesium, lead, manganese, silicon or other ingredients.

[0016] In the Figures 1A and 1BThe aluminum profile 2 is completely covered by another aluminum alloy. Figure 2 A modified composite profile 1' is shown in which an aluminum profile 2' is not completely encased by another aluminum alloy, but rather a section 3' only partially surrounds the aluminum profile 2'. The strip-shaped section 3' is provided only on one side of the aluminum profile 2', but can also be arranged on multiple sides. The composite profile 1' can also be produced by co-extrusion by first extruding the aluminum profile 2' and then co-extruding it with a section 3' made of a modified aluminum alloy in another extrusion device.

[0017] The Figures 1A to 3The composite profiles 1' shown can alternatively also be produced by a different process in which first a first aluminum profile 2 or 2' is extruded from a first aluminum alloy and then a second aluminum profile 3 or 3' is extruded from a second aluminum alloy, wherein the second aluminum alloy is designed differently from the first aluminum alloy, in particular with regard to the additives of the aluminum alloy, i.e. the proportion of copper, magnesium, lead, manganese, silicon, or other ingredients. The first aluminum profile 2 or 2' is then connected to the second aluminum profile 3 or 3' using a thermal joining process, in particular by welding, for example by laser welding. This produces a one-piece composite profile 1 or 1' from two different aluminum alloys.

[0018] The composite profile 1 or 1' according to the invention can also comprise more than just two different sections made of different aluminum alloys, for example, three or more sections made of different aluminum alloys. Furthermore, the shape of the produced composite profile can be completely different, being designed as a hollow profile or an angular profile.

[0019] Regardless of the manufacturing method of the composite profile 1 or 1', it can then be connected to other profiles, for example, with at least one plastic insulating bar, which can be secured to the composite profile via formed fixing bars. The at least one plastic insulating bar can be connected to another aluminum profile or a composite profile on the side facing away from the composite profile.

[0020] In Figure 4a corner region of a window, a door or a facade is shown, wherein the corner region 10 comprises two frame profiles 11, each comprising an inner shell 12, preferably made of an aluminum profile, at least one insulating web 13 and an outer shell 14. The outer shell 14 forms a first aluminum profile which is connected to a second aluminum profile 15 via a thermal joining process, so that the outer shell is designed as a composite profile according to the invention. Due to the co-extruded aluminum alloys, a corner connector, T-connector or wire feed can be dispensed with during a joining process, for example by welding, by means of an auxiliary joining part or an insert. Preparatory processing of the profile required for welding can be minimized or eliminated entirely.

[0021] In Figure 5A section through a window profile 20 and a frame profile 30 is shown. The window profile 20 comprises an inner shell 21 made of an extruded aluminum profile, two insulating webs 22 and 23 made of plastic, and an outer shell made of a composite profile consisting of a first aluminum profile 24 and a second aluminum profile 25, which are connected to one another via one or more connecting webs 26. The first aluminum profile 24 and the second aluminum profile 25 are preferably connected to one another by thermal joining, in particular by welding, at the connecting web 26.

[0022] The frame profile 30 also comprises an inner shell 31 made of an extruded aluminum profile and two insulating webs 22 and 32 made of plastic, which are connected by a composite profile according to the invention. The composite profile comprises a first aluminum profile 34 and a second aluminum profile 35 made of a modified aluminum alloy, which are connected to each other by thermal joining at two connecting webs 36.

[0023] The co-extruded or thermally bonded aluminum profiles 34 and 35 allow the required alloy to be introduced into at least one joint and designed to withstand the load. The introduction of the alloys during the extrusion process enables optimal bonding to the main material without inclusions or other defects that could be a risk with subsequent application.

[0024] The aluminum profiles can be manufactured using these processes both as solid profiles and as hollow profiles. List of reference symbols

[0025] 1, 1'Composite profile 2, 2'Aluminum profile 3, 3'Aluminum profile 10Corner area 11Frame profile 12Insulating bar 13Insulating bar 14Outer shell 15Aluminum profile 20Window profile 21Inner shell 22Insulating bar 23Insulating bar 24Aluminum profile 25Aluminum profile 26Connecting bar 30Facade frame profile 31Inner shell 32Insulating bar 33Insulating bar 34Aluminum profile 35Aluminum profile 36Connecting bar

Claims

1. A method for producing an extruded composite profile (1, 1') comprising the following steps: - feeding an aluminum profile (2, 2') to an extrusion device; - adding an aluminum alloy during extrusion for co-extrusion, and - producing an extruded composite profile (1, 1') with sections having a different alloy composition.

2. Method according to claim 1, characterized in that the addition of the aluminum alloy is carried out by adding a granulate and / or a powder.

3. Method according to claim 1 or 2, characterized in that the extruded composite profile has integrally formed sections made of different aluminum alloys.

4. Method according to one of the preceding claims, characterized in that When the aluminum alloy is added, it is partially added around the aluminum profile.

5. Method according to one of claims 1 to 3, characterized in thatwhen adding the aluminum alloy, it is added completely enveloping the aluminum profile (2).

6. A method for producing an extruded composite profile (1, 1') comprising the following steps: - extruding a first aluminum profile (2, 2') from a first aluminum alloy; - extruding a second aluminum profile (3, 3') from a second aluminum alloy that is different from the first aluminum alloy, and - joining the first aluminum profile (2, 2') to the second aluminum profile (3, 3') using a thermal joining process.

7. Method according to claim 6, characterized in that the first aluminum profile (2, 2') is welded to the second aluminum profile (3, 3').

8. Method according to one of the preceding claims, characterized in that the composite profile (1, 1') is connected to at least one insulating web (22, 23, 32, 33) made of plastic by forming.

9. Composite profile (1, 1') with at least two integrally formed sections made of a different aluminum alloy, which is connected to another profile made of aluminum via at least one insulating web (22, 23, 32, 33) made of plastic.

10. Frame for a window, a door or a facade with at least one composite profile (1, 1') according to claim 9.

Images