Window frame manufacturing method

Abstract

To provide a method for manufacturing window frames that can produce window frames with high dimensional accuracy. [Solution] A method for manufacturing a window frame, comprising a preparation step of preparing a frame made of resin, and an annealing step of annealing the frame.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a window frame, and more specifically, relates to a method for manufacturing a resin window frame using a resin frame body.

Background Art

[0002] Conventionally, as residential windows, those with window frames (for example, the frame bodies of residential sashes) made of aluminum have been widely used. Residential windows are required to have good heat insulation properties and sound insulation properties. Recently, in response to this demand, resin window frames mainly composed of resin are being increasingly used as residential windows. In particular, centered on cold regions, resin window frames with excellent heat insulation properties are becoming widely prevalent. Various types of such resin window frames have been proposed. For example, Patent Document 1 proposes a method for manufacturing a resin sash, in which a polyvinyl chloride powder containing 60 mass% or more of polyvinyl chloride with a polymerization degree of 1000 is mixed with additives to prepare a kneaded product, and the kneaded product is subjected to extrusion molding. This document discloses that four members are joined to form the frame of a resin sash.

[0003] In addition, since resin window frames are lighter in weight than metal window frames, the use of resin window frames can improve workability during the manufacture and installation of residential windows. Incidentally, in general, since resins have a larger thermal expansion coefficient than metals, resin window frames inherently have a problem that dimensional variations, warpage and the like are more likely to occur due to changes in the external environment and the like, compared with metal window frames.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] The primary objective of this invention is to provide a method for manufacturing resin window frames that can suppress dimensional changes and warping that may occur due to changes in the external environment. [Means for solving the problem]

[0006] A method for manufacturing a window frame according to one embodiment of the present invention includes a preparation step of preparing a frame made of resin and an annealing step of annealing the frame.

[0007] In the manufacturing method of a window frame according to one embodiment of the present invention, the frame body may be formed by combining a plurality of resin members in the preparation step. In the method for manufacturing a window frame according to one embodiment of the present invention, the frame body may be a rectangular frame body. A method for manufacturing a window frame according to one embodiment of the present invention may include, after the annealing step, a bonding step of bonding wood to at least a portion of the surface of the frame. In the method for manufacturing a window frame according to one embodiment of the present invention, the wood may be heated in the pasting step. A method for manufacturing a window frame according to one embodiment of the present invention may include a coloring step of coloring at least a portion of the surface of the frame before the annealing step. [Effects of the Invention]

[0008] According to the window frame manufacturing method of the present invention, it is possible to manufacture a resin window frame that can suppress dimensional changes and warping that may occur due to changes in the external environment. [Brief explanation of the drawing]

[0009] [Figure 1] This is a plan view showing an example of a resin frame used in the manufacturing method of a window frame according to the present disclosure. [Figure 2] This is a front view showing an example of a window using a manufactured window frame. [Figure 3] This is a plan view showing an example of a method for forming a resin frame prepared in the preparation process. [Figure 4] This is a plan view showing an example of a method for forming a resin frame prepared in the preparation process. [Figure 5] These are plan views of the test specimens and frames used in the examples and comparative examples, where (a) shows the four test specimens forming the frame, (b) shows the frame with the four test specimens welded together, and (c) shows the positions where the wood was attached. [Modes for carrying out the invention]

[0010] Embodiments of the present invention will be described below with reference to the drawings. It should be noted that the present invention can be implemented in many different forms, and is not limited to the embodiments described below. Furthermore, in order to clarify the explanation, the drawings may schematically represent the width, thickness, shape, etc., of each part compared to the actual embodiment; however, these are merely examples and do not limit the interpretation of the present invention. In addition, in this specification and the drawings, elements similar to those described above in previously shown drawings are denoted by the same reference numerals, and detailed explanations may be omitted as appropriate.

[0011] <<Window frame manufacturing method>> The method for manufacturing a window frame according to the embodiments of this disclosure (hereinafter referred to as the manufacturing method of one embodiment) includes a preparation step and an annealing step. Hereinafter, each step in the manufacturing method of one embodiment will be described with an example.

[0012] (preparation process) The preparation step is the step of preparing a resin frame 1. The resin frame 1 has an opening X (which may also be called a hole) formed by (closed by) the inner edge of the frame 1 (see Figure 1). The resin frame 1 may have one opening X (see Figures 1(a) to (d)) or multiple openings X (see Figure 1(e)). According to one embodiment of the manufacturing method using the resin frame 1, a window frame with excellent heat insulation and sound insulation properties can be manufactured. In addition, the weight of the manufactured window frame can be reduced by using the resin frame 1.

[0013] In this specification, "resin frame" means a frame containing more than 50% by mass of resin relative to its total mass. For example, resin frame 1 contains 70% by mass or more of resin relative to its total mass. For example, resin frame 1 contains more than 80% by mass of resin relative to its total mass. Resin frame 1 is synonymous with a frame containing resin as its main component. Hereafter, when "frame" is used, it means a resin frame. Furthermore, in this specification, "resin window frame" means a resin frame that has undergone an annealing process. A resin window frame manufactured by the manufacturing method of one embodiment only needs to include a resin frame that has undergone an annealing process, and may include not only a resin frame, but also, for example, wood or coloring materials as described later.

[0014] There are no limitations on the resin that constitutes the frame 1, and various resins can be appropriately selected and used. Examples of resins include polyvinyl chloride, polypropylene, polyethylene, polycarbonate, polystyrene, polyamide, polyimide, polyamideimide, polyethylene terephthalate, epoxy, acrylic, acrylonitrile-butadiene-styrene (ABS), and melamine. The frame 1 may also be made of a resin other than those listed above. Among these resins, polyvinyl chloride is suitable as the resin for the frame 1 because it has low thermal conductivity and high light resistance.

[0015] The resin constituting the frame 1 may be of one type or two or more types. If the frame 1 contains multiple resins, the total mass of the multiple resins must be greater than 50% of the total mass of the frame 1. Furthermore, the frame 1 may be a single-layer structure or a laminated structure formed by stacking multiple layers. As an example, the frame 1 is a laminated structure formed by stacking a first resin frame 1 and a second resin frame 1.

[0016] The outer shape of frame 1 (the outer edge shape of frame 1) is not limited, and examples include a rectangle (see Figures 1(a), (b), (e)), a polygon, a circle, an ellipse (see Figures 1(c), (d)), and the like. Other shapes may also be used. The shape of the opening provided in frame 1 is not limited, and may be the same as the outer shape of frame 1 (see Figures 1(a), (c)), or may be different (see Figures 1(b), (d)). Figure 1 is a plan view showing an example of frame 1 when viewed in plan.

[0017] The window frame produced by the manufacturing method of one embodiment can be used, for example, as a conventionally known window frame, and is not limited to window frames for residential windows. Figures 2(a) to (h) are front views showing examples of windows using the window frame produced by the manufacturing method of one embodiment, where (a) is a vertical projected window, (b) is a vertical projected window + vertical projected window (multi-unit window), (c) is a vertical projected window + fixed window (multi-unit window), (d) is a horizontal projected window, (e) is a horizontal projected window + horizontal projected window (multi-unit window), (f) is a horizontal projected window + fixed window (multi-unit window), (g) is a vertical projected window + fixed window + vertical projected window (multi-unit window), and (h) is a horizontal projected window + fixed window (multi-unit window).

[0018] The size and thickness of frame 1 are not limited in any way, and may be appropriately determined according to the use of the window frame. The thickness of frame 1 as an example is 0.1 mm or more and 10 mm or less. The thickness of frame 1 as an example is 0.5 mm or more and 3 mm or less. As an example, the frame body has a rectangular outer shape, and the vertical and horizontal lengths are each about 300 mm to 3000 mm.

[0019] The frame 1 prepared in the preparation step may be formed by a predetermined method, or may be an off-the-shelf product. Examples of the method for forming the frame 1 include: (i) a method of using a plurality of resin members 2a (see Fig. 3(a)) and fixing these resin members 2a to each other by welding or with various fixing members such as adhesives and nails (see Fig. 3(b)); and (ii) a method of preparing a resin plate 2b having no opening (see Fig. 4(a)) and punching this resin plate 2b at the planned punching region 2c (see Fig. 4(b)). The frame 1 may be formed by other methods. In the method for forming the frame 1 of the embodiment shown in Fig. 1, both end portions of each of the four resin members are cut at approximately 45 degrees with respect to the longitudinal direction, and the cut surfaces of the resin members to be joined are welded together to form the frame 1. Instead of the method for forming the frame 1 of the embodiment shown in Fig. 1, for example, two rectangular parallelepiped resin vertical members and two rectangular parallelepiped horizontal members may be prepared, and these may be mechanically fixed, for example, to form the frame 1. A plurality of members having other shapes may be used to form the frame 1.

[0020] (Annealing Step) The annealing step is a step of annealing the resin frame 1 prepared in the preparation step. Through the annealing step, a window frame in which the resin frame 1 is annealed can be produced.

[0021] The production method of one embodiment, in which the resin frame 1 is annealed, that is, the resin molded into a frame shape is annealed, can produce a window frame with good dimensional accuracy, as compared with a comparative production method in which a plurality of resin members are annealed and the plurality of annealed resin members are combined to form a frame 1. In addition, by annealing the resin frame 1, the residual stress of the resin can be relieved, and the occurrence of dimensional variation, warpage, etc. in the produced window frame due to changes in the external environment, for example, changes in temperature and humidity, can be suppressed. In addition, the occurrence of cracks and the like that may occur when an impact is applied to the frame 1 can be suppressed.

[0022] Furthermore, if the frame 1 prepared in the preparation step is a combination of multiple resin members 2a (see Figure 3(a)), and the window frame is manufactured without annealing the frame 1, then dimensional variations and warping may be more pronounced in the manufactured window frame. Considering this point, the manufacturing method of one embodiment is suitable when the frame 1 prepared in the preparation step is a frame 1 made by combining multiple resin members 2a (see Figure 3(b)).

[0023] Furthermore, as is clear from the results of the examples and comparative examples described later, if the components of the manufacturing method of one embodiment are not satisfied, it is not possible to sufficiently suppress dimensional changes and warping in the manufactured window frame.

[0024] In one embodiment of the manufacturing method, regardless of the annealing conditions, performing at least annealing can suppress dimensional variations and warping in the manufactured window frame compared to cases where annealing is not performed. Therefore, there are no limitations on the various conditions in the annealing process.

[0025] As an example, the annealing process involves annealing the frame 1 at a temperature below the glass transition temperature (Tg) of the resin constituting the frame 1 for approximately 2 to 3 hours. The annealing time may be less than 2 hours or longer than 3 hours. The glass transition temperature (Tg) as used in this specification is the value obtained by scanning calorimetry (DSC) in accordance with JIS-K-7121.

[0026] If the frame 1 is composed of multiple resins, the frame 1 should be annealed at a temperature below the glass transition temperature (Tg) of the resin with the highest content. Alternatively, the frame 1 should be annealed at a temperature below the glass transition temperature (Tg) of the resin with the lowest glass transition temperature (Tg) among the multiple resins. Preferred annealing conditions are to anneal the frame 1 at ±15°C of the reference temperature, where the reference temperature is the glass transition temperature (Tg) of the resins constituting the frame 1 minus 15°C.

[0027] There are no limitations on the annealing atmosphere; it may be carried out at atmospheric pressure, under reduced pressure, or under an inert gas atmosphere. For the annealing equipment, conventionally known annealing furnaces or the like can be appropriately selected.

[0028] (Pasting process) The bonding step is a step in which wood is bonded to at least a portion of the surface of the frame 1 after the annealing step. In this case, the window frame manufactured by the manufacturing method of one embodiment will have a laminated structure in which the frame 1 and the wood are laminated together. The bonding step is an optional step in the manufacturing method of one embodiment. According to the manufacturing method of one embodiment that has a bonding step, the design of the manufactured window frame can be enhanced. Furthermore, by performing the bonding step after the annealing step, it is possible to suppress lifting, peeling, and even displacement of the bonded wood.

[0029] Various types of wood that are conventionally known can be appropriately selected and used. Examples of wood types include solid wood, composite wood, and plywood. Examples of solid wood include oak, beech, maple, teak, walnut, cedar, cypress, and pine.

[0030] There are no restrictions on the thickness of the wood; it should be determined considering factors such as workability and durability. Preferably, the wood thickness is 0.1 mm to 10 mm, and more preferably 0.2 mm to 3 mm.

[0031] There are no limitations on the placement of the wood. One example of the attachment process is to attach wood to the entire surface of the frame 1. Another example of the attachment process is to attach wood to a portion of the surface of the frame 1. Another example of the attachment process is to attach wood to at least a portion of either the front or back surface, or both, of the frame 1. In addition, wood may be attached to at least a portion of the outer wall surface or the inner wall surface of the frame 1. The thickness of the wood may be varied depending on where it is attached.

[0032] One example of the bonding process is to use an adhesive. Alternatively, adhesive tape or adhesive sheets may be used instead of adhesive. Examples of adhesives include polyurethane, polyolefin, polyester, acrylic resin, epoxy resin, urea resin, melamine resin, phenolic resin, vinyl chloride-vinyl acetate copolymer, polyimide, polyvinyl acetate, and synthetic rubber. Among these, chloroprene rubber and nitrile rubber, both types of synthetic rubber, are preferred due to their good adhesion to both the resin and the wood.

[0033] When attaching wood to frame 1 using adhesive, the adhesive may be applied to either frame 1 or wood. Alternatively, the adhesive may be applied to both frame 1 and wood. Furthermore, when using adhesive, surface treatment may be performed to improve adhesion between frame 1 and wood. Examples of surface treatments include blasting, plasma treatment, and corona discharge treatment. Degreasing treatment may also be performed.

[0034] A preferred form of the bonding process involves bonding the wood to the frame 1 while heating the wood. For example, the heating temperature of the wood is 50°C or higher. For example, the heating temperature of the wood is 100°C or higher. A preferred form of the bonding process involves heating the wood while pressing it. According to the preferred form of the bonding process, the moisture contained in the wood can be removed by heating, and a window frame with less dimensional variation and warping can be manufactured compared to when the wood is not heated.

[0035] Furthermore, the surface of the wood may be treated after the bonding process. Examples of surface treatments include painting the wood surface with paint and polishing the wood surface. Examples of paints include penetrating paints and film-forming paints. Examples of penetrating paints include oil stains. Examples of film-forming paints include varnishes, polyurethanes, and acrylic paints. Painting can be done using various conventionally known methods such as brushes, airbrushes, and sprays. Alternatively, instead of performing surface treatment on the wood after the bonding process, the bonding process may be performed using wood that has been pre-surface-treated.

[0036] In the above explanation, we used the example of attaching wood as the attachment process, but instead of wood, decorative materials such as decorative sheets or wallpaper may be attached to the frame 1.

[0037] (Coloring process) The coloring step is a step of coloring at least a portion of the surface of the frame 1. The coloring step is an optional step in the manufacturing method of one embodiment. According to the manufacturing method of one embodiment having a coloring step, the aesthetic appeal of the manufactured window frame can be enhanced. The coloring step may be performed before the annealing step or after the annealing step. A preferred form of the manufacturing method of one embodiment is to perform the coloring step before the annealing step. Performing the coloring step before the annealing step can improve the adhesion of the paint and colorant to the frame 1.

[0038] Examples of coloring methods for frame 1 include coloring by painting and coloring by printing. Examples of paints used for painting include silicone paint, fluoropolymer paint, lacquer paint, acrylic paint, enamel paint, and urethane paint. There are no limitations on the hue of these paints, and they should be appropriately selected according to the design requirements of the window frame. Coloring by painting can be carried out using various conventionally known methods such as brushes, airbrushes, and sprays.

[0039] There are no limitations on the coloring location. One example of the coloring process is to color the entire surface of frame 1. Another example of the coloring process is to color a portion of the surface of frame 1. Another example of the coloring process is to color at least a portion of either the front surface or the back surface, or both, of frame 1. In addition to this, at least a portion of the outer wall surface or the inner wall surface of frame 1 may also be colored.

[0040] In the above explanation, the coloring process involved using paint or the like to color the frame 1, but it is also possible to use a pre-colored frame 1. Specifically, a frame 1 containing resin and a coloring agent can also be used. [Examples]

[0041] Next, the present invention will be described in more detail with reference to examples and comparative examples.

[0042] (Preparation of test specimens) Three sets of polyvinyl chloride test specimens X (test specimens X-1 to X-4) shown in Figure 5(a) were prepared (for forming window frames A-1, B-1, and C-1). Each test specimen had a thickness of 2 mm.

[0043] (Formation of frame A-1) For one set of test specimens X prepared as described above, the four corners of each specimen were welded together to form frame A-1 (see Figure 5(b)).

[0044] (Annealing treatment) The test specimen X (1 set) prepared as described above, and the frame A-1 formed as described above, were placed in a furnace controlled to 55°C to 65°C and subjected to annealing treatment for 3 hours.

[0045] (Formation of window frame) The frame A-1 that underwent the above annealing treatment was designated as window frame A-1. The four corners of the annealed specimen X were welded together to form window frame B-1. The four corners of test piece X, which had not undergone the annealing treatment described above, were welded together to form window frame C-1.

[0046] (Dimensional evaluation) Each of the window frames formed as described above (window frame A-1 to window frame C-1) was placed in a furnace controlled to 65°C to 75°C and heated for 3 hours. The dimensions of each window frame were measured a total of five times: before being placed in the furnace (before the test), 1 hour, 2 hours, and 3 hours after being placed in the furnace, and 3 hours after being removed from the furnace (after the test). The dimensional measurement results are shown in Table 1. "a-1", "a-2", "a-3", and "a-4" in Table 1 correspond to the symbols "a-1", "a-2", "a-3", and "a-4" in Figure 5(b). Window frame A-1 is the window frame of the example (window frame of Example 1-1), and window frames B-1 and C-1 are the window frames of the comparative examples (window frames of Comparative Examples 1-1 and 2-1).

[0047] [Table 1]

[0048] (Wood gluing) Window frames A-1, B-1, and C-1 were prepared using the same method as described above. Each of these prepared window frames was placed in a furnace controlled to 65°C to 75°C. As shown in Figure 5(c), a piece of wood (white oak) approximately 2 mm thick was attached to the surface of each window frame while heating it at over 100°C. Window frames A-1, B-1, and C-1 with the wood attached were designated as window frames A-2, B-2, and C-2, respectively. Window frame A-2 is the window frame of the example (window frame of Example 1-2), and window frames B-2 and C-2 are the window frames of the comparative examples (window frames of Comparative Examples 1-2 and 2-2).

[0049] (Evaluation of wood lifting and peeling) Each window frame (window frame A-2 to window frame C-2) formed as described above was placed in a furnace controlled to 65°C to 75°C and heated for 3 hours. The attached wood was visually inspected before being placed in the furnace (before the test), 1 hour, 2 hours, and 3 hours after being placed in the furnace, and 3 hours after being removed from the furnace (after the test) to check for peeling or lifting. The lifting and peeling of the wood was evaluated based on the evaluation criteria below. The evaluation results are shown in Table 2.

[0050] [Evaluation Criteria] A: There is no visible lifting or peeling of the wood. NG: There is visible lifting or peeling of the wood.

[0051] (Evaluation of wood displacement) The gaps at the joints of the timber (Y1-Y4 (4 locations) in Figure 5(c)) were measured 1 hour, 2 hours, and 3 hours after the timber was placed in the furnace, and the average value of these gaps was calculated. The calculation results are shown in Table 2. In addition, the displacement of the timber was evaluated based on the evaluation criteria below. The evaluation results are also shown in Table 2.

[0052] [Evaluation Criteria] A: The average gap size at the joints of the wood is less than 0.9 mm. B: The average gap size at the joints of the wood is 0.9 mm or more but less than 1 mm. NG: The average gap between the joints of the wood is 1 mm or more.

[0053] [Table 2] [Explanation of symbols]

[0054] 1...Frame 2a... Resin component 2b...Resin board 2c... Planned punching area X...Opening of the frame

Claims

1. A method for manufacturing a window frame, Preparation process for preparing a resin frame, This includes an annealing step of annealing the frame, A method for manufacturing window frames.

2. In the preparation step, a plurality of resin members are combined to form the frame. A method for manufacturing a window frame according to claim 1.

3. The aforementioned frame is a rectangular frame. A method for manufacturing a window frame according to claim 1.

4. The process includes, after the annealing step, a bonding step in which wood is attached to at least a portion of the surface of the frame, A method for manufacturing a window frame according to any one of claims 1 to 3.

5. In the aforementioned bonding process, the wood is heated. The method for manufacturing a window frame according to claim 4.

6. Prior to the annealing step, a coloring step is included in which at least a portion of the surface of the frame is colored. A method for manufacturing a window frame according to any one of claims 1 to 3.

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