Plastic Profile Welding Bead Pressing for Clean Joints
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Solution Overview
Problem
The existing methods for joining plastic profiles in window or door frames often result in unsightly elevations or sweat beads due to dimensional tolerances and clumsy joining processes, leading to undesirable optical and haptic outcomes.
Innovation Solution
A method where plastic profiles are merged to form a mechanically stable connection, with a pressure body exerting force at an angle to the impact edge, allowing the welding bead to be pressed into the impact area without heating, and using a device with a retaining body and pressure body to move along the impact edge, eliminating protrusions without additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plastic profiles are joined with minimal excess material, then manufacturing precision is improved, but the joining process becomes more difficult due to dimensional tolerances and the formation of unsightly elevations
Solution Approach 1:
The patent applies preliminary action by creating a recess in the impact area before the welding process. This recess is prepared in advance to accommodate the excess material that will be generated during welding, preventing the formation of unsightly elevations while maintaining the benefits of minimal excess material usage. The recess acts as a pre-prepared cavity that guides the material flow and ensures a clean joint appearance.
2Ease of manufacture
If excess material is used in plastic profiles, then ease of joining is improved, but unsightly elevations and sweat beads form at the impact edge
Solution Approach 1:
The patent extracts the problematic excess material by creating a recess in the impact area that specifically targets and accommodates the sweat beads and elevations. The recess is positioned to receive the displaced plastic material during welding, effectively removing the harmful surface protrusions while preserving the structural integrity of the joint. This extraction approach eliminates the visual defects without compromising the strength of the connection.
3Strength
If welding is used to join plastic profiles, then mechanical stability is improved, but unsightly protrusions and elevations are generated at the impact edge
Solution Approach 1:
The patent applies local quality by creating a recess specifically in the impact area where the two plastic profiles meet, while leaving the rest of the profile surfaces unchanged. This localized modification targets only the problematic region where material displacement occurs during welding, allowing the weld to maintain its mechanical strength while the recess captures and contains the excess material that would otherwise form unsightly protrusions on the visible surface.
4Loss of time
If traditional welding without heating is used, then production time is reduced, but the ability to press profile protrusions into the impact area is limited
Solution Approach 1:
The patent applies preliminary action by pre-forming the recess in the plastic profiles before the welding process. This preliminary geometric preparation creates a ready-made cavity that guides the material flow during welding, enabling the profile protrusions to be pressed into the impact area effectively even without extended heating time. The recess acts as a pre-prepared receptacle that facilitates the integration of excess material into the joint structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach eliminates unsightly protrusions and elevations at the joint, improving the optical design and mechanical stability of the connection without extending production time or requiring further processing steps.
Implementation Method 1
a pressure body (4) which is intended to be moved by the retaining body (3) along the longitudinal extension of the impact edge (2), wherein the pressure body (4) exerts a force directed at right angles to the longitudinal extension of the impact edge (2) on the impact edge (2)
Implementation Method 2
a heater (8) which is intended to heat at least the area of the impact edge (2)
Implementation Method 3
the surfaces of the plastic profiles to be joined (usually the mitered end areas of the plastic profiles) are first heated (until they become plastic) and then moved into a joining step
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3a~3c
AI summary
The invention relates to a method for joining two plastic profiles, in particular for producing a sash or frame, characterized by the sequence of the following steps: - Bringing the two plastic profiles together in such a way that, at the latest upon contact of the surfaces to be joined of the plastic profiles, a mechanically stable connection is formed and an abutting edge is formed between the plastic profiles, - Moving a pressure body along the longitudinal extent of the abutting edge, wherein the pressure body exerts a force, preferably directed perpendicular to the longitudinal extent of the abutting edge, on the abutting edge.