Thermally Separated Reinforcement Profiles Continuous Production
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Solution Overview
Problem
Existing methods for producing thermally separated reinforcement profiles, such as those for window and door frames, often result in thermal bridges and require the removal of metal profile areas after plastic injection, which is inefficient and not suitable for continuous production.
Innovation Solution
A continuous process involving cold-formed metal profiles with edge webs, where a fast-hardening plastic is injected between the profiles in a continuous flow, with a support system to prevent sticking and allow for the formation of a permanent thermal separation without removing metal profile areas, and optional perforations for plastic foam introduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal profiles with bridging webs are used to support plastic during injection, then the plastic can be properly supported during curing, but the bridging webs form thermal bridges and must be removed after injection
Solution Approach 1:
The harmful bridging webs that create thermal bridges are completely removed after plastic injection. The process extracts only the necessary support function during curing, then eliminates the supporting structure itself to prevent thermal bridging in the final product.
Solution Approach 2:
Metal profiles with bridging webs are prepared in advance before plastic injection. The bridging webs are pre-formed to provide support during the injection and curing process, then removed after serving their temporary purpose.
2Device complexity
If metal profiles are formed with smooth webs pointing perpendicularly to the main surface, then the structure is simple, but the plastic cannot be properly supported and requires complex web removal procedures
Solution Approach 1:
The metal profiles have locally differentiated surfaces: smooth webs on one side for structural simplicity, and roughened webs on the other side for plastic anchoring. This local quality differentiation provides both structural support and manufacturing ease without requiring web removal.
Solution Approach 2:
The support function and the final profile structure are merged into a single integrated component. The roughened webs remain as part of the final structure, eliminating the need for separate web removal operations while providing continuous plastic support.
3Object-affected harmful factors
If plastic is injected between metal profiles with perpendicular webs, then thermal separation is achieved, but the process requires discontinuous operations including web removal
Solution Approach 1:
The plastic injection process continues uninterrupted between metal profiles. The roughened webs provide continuous support throughout the injection and curing process, eliminating discontinuous web removal operations and enabling continuous production.
Solution Approach 2:
The metal profiles with roughened webs are prepared in advance to provide continuous support during the entire plastic injection and curing process, eliminating the need for interrupting production to remove webs.
4Ease of manufacture
If the support surface is prepared with release agents like diesel oil or fat-soluble liquids, then plastic does not stick to the support surface, but additional preparation steps are required
Solution Approach 1:
The roughened web structure provides self-release properties without requiring external release agents. The surface texture itself prevents plastic adhesion, making the profile self-sufficient for easy plastic removal without additional chemical preparations.
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
Enables the efficient and continuous production of thermally separated reinforcement profiles with reduced thermal bridges and no need for metal profile area removal, suitable for various applications including windows, doors, conservatories, and air conditioning units.
Implementation Method 1
a fast-hardening plastic is injected between the edge profiles in a continuous flow
Implementation Method 2
The metal profiles can be positioned in such a way that their edge webs slide on a support surface that has been prepared, for example, with diesel oil or a fat-soluble liquid to prevent plastic from sticking
Data Source
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AI summary
The method involves providing a plastic insert between two metal profiles. The two metal profiles are produced in the path of the cold processing, where edge profiles are provided with a reverse crank. The metal profiles are positioned opposite to each other and a quick hardened plastic is injected between an edge profiles in continuous passage. An independent claim is also included for a device for preparing a thermally separated reinforcing profile, particularly for window and door frame.