EP1242709B2 - Plastic filled or hollow chamber profiles, especially for composite profiles - Google Patents

Abstract

The invention presents a composite profile for use in the production of windows, doors, facade elements or the like, having inner and outer metallic profiles spaced at a specific distance from each other by a plastic profile. The invention further proposes that the plastic profile contain a surface of a solid, non-porous first plastics material, in a core region, a fine-pored cellular structure of a second plastics material. Additionally, the plastic profile may either be a solid, multilayer profile or a hollow profile. Such plastics profiles are particularly adapted to absorb tensile, bending and/or pressure loads.

Description

The invention relates to solid or hollow chamber plastic profiles, in particular for absorbing tensile, bending and / or compressive load, as they are used in particular as Isolierstege in composite profiles of metal profile parts used.

Known profiles of this type are for example from the DE 32 03 631 A1 or the DE 38 01 564 A1 known and used as a thermal insulation profiles between metal profile parts and made of high-strength plastic with poor thermal conductivity properties, such as a glass fiber reinforced polyamide. These composite profiles are mainly used in the manufacture of window or facade elements.

These composite profiles and thus also the solid or hollow profiles made of plastic are exposed to significant effects, such as wind loads, vertical loads, in particular caused by the weight of a glazing and especially stemming from temperature differences between the outside and the inside arranged metal profile part of the composite profile. The less the plastic material of the insulating profiles under climatic influence, namely temperature and humidity changes, the lower the resulting stresses at the interface of plastic and metal profile.

So far, attempts have been made with higher filler degrees of the plastic material used, in particular using mineral reinforcing and fillers, in particular glass fibers, to influence the expansion behavior of the plastic materials low, namely to reduce their expansion coefficient.

Higher filling levels, however, also lead to a number of disadvantages. In addition to the increased raw material costs and higher weight of the insulating profiles, problems arise in the processing of the raw material, in particular with regard to wear and productivity. After extrusion and solidification, glass-fiber reinforced plastics can exhibit undesired anisotropies, residual stresses, greatly decreasing ductility and, above all, a higher thermal conductivity than the pure plastic.

According to the DE 38 01 564 A1 an attempt is made to reduce the thermal conductivity of the insulating profile by incorporating small hollow glass spheres. However, this technology is quickly reaching its limits, and in view of the stricter requirements of energy conservation by the legislator and the manufacturer of composite profiles, this technology no longer meets all requirements.

A generic profile is also used by the JP-A-03 240 515 specified.

The object of the invention is to develop the above-mentioned full or hollow chamber profile so that the disadvantages described above are pushed back as far as possible.

This object is achieved by the combination of features of claim 1 and claim 12.

The cell structure of the core region is selected closed cell, so that a plurality of insulating gas volumes in the plastic profile is present. Thus, an optimal heat transfer resistance is obtained. The fine-poredness and closed-celledness of the core region is also important from the viewpoint that the mechanical properties do not decrease in parallel with the decrease in density, but are largely retained.

The profiles of the invention can be prepared analogously to those in the DE 32 03 631 C2 and the DE 195 10 944 C1 described method. The fine-pored core is thereby by foaming the second plastic material by means of known agents such. As liquid CO ₂ , nitrogen or azodicarbonamide.

By limiting the compact, non-porous first plastic material to the formation of a surface layer of the plastic profile and the use of a core region with a fine-pored cell structure, a significant reduction in the thermal conductivity of the profile is achieved overall. The reduction of the thermal conductivity is due essentially to the reduction in density or the gas inclusions in the core area. This results in parallel to a lower weight of the profile and leads to significant savings in raw material in the production of the plastic profile. Depending on the wall thickness of the surface layer (s) and the application, the possible savings in raw materials are up to 60%. With the same dimensions of the profile can be achieved with only small losses in the stiffness factor (transverse bending stiffness) to significantly reduced meter weights.

Compared to conventional profiles, the profile thickness can be made larger at the same meter weight, resulting in significantly higher stiffness or bending strength of the plastic profile. Surprisingly, for example, doubled transverse stiffness factors are obtained with only slightly increased wall thickness, and this results in particular from the use of fine-pored structures in the core region, whose mechanical properties have no linear relationship with the density, as is the case of free-blown, known large-pore Cell structures is common.

In order to achieve optimal mechanical properties, in particular strength, it is ensured that the porosity or the cell structure is substantially uniform over the entire cross section of the core region. In particular, it is important to keep the cell size within a given framework, for example within the range recommended below, and to avoid coarser cells at isolated points in the cross section.

In the case of the hollow chamber profiles with inner surface layer of compact plastic material, the structure of the profile will preferably be formed such that the core region with its cell structure is completely enclosed by the surface layer and the inner surface layer defining the hollow chamber or cavities.

In this case, the surface layer, the core region and the inner surface layer are preferably formed as sandwich structures at least in partial regions of the profile, in which the surface layer, the inner surface layer and the core region enclosed between them form layers arranged essentially parallel to one another.

The first, second and third plastic materials used to make the inventive profiles may be the same or different and may contain reinforcing agents, fillers, modifiers and / or additives. The reinforcing materials are short, long and / or continuous fibers, in particular glass, carbon, aramid or natural fibers are used. Suitable fillers are glass beads, glass bubbles, wollastonite, mica and nanoparticles.

The group of modifiers includes impact modifiers, UV heat stabilizers, conductivity substances, nucleating agents, coupling agents, etc.

For profiles which have an integrally formed flange, which is used by a corresponding groove of the metal profiles of a composite thermal insulation profile, it is recommended to provide the flange on its surface at least partially with a fine-pored coating, for example by coextrusion. As a result, the flange can be made somewhat undersized with respect to the groove of the associated metal profile receiving it, and the groove walls can be pressed against the flange by a knurl operation and deform the fine-pored coating. As a result, a particularly good positive engagement between the flange of the profile and the groove of the metal profile is achieved.

The mean cell size of the cell structure of the core region should be in particular in the range of 0.005 to 0.1 mm (diameter), preferably in the range of 0.02 to 0.05 mm. In these areas, there is an optimum of mass saving and preservation of mechanical properties.

The density of the material in the core area can be reduced by up to about 60% compared to the density of the raw material.

The plastic materials which are suitable as raw materials for the production of the profiles according to the invention, ranging from thermoplastic, thermoset to elastomeric plastic materials or mixtures thereof.

Normally, the same raw material will be used for the first, the second and optionally the third plastic material, whereby it can be achieved by appropriate process control that the compact surface layer results quasi automatically and for the formation of the compact surface layer next to the porous core region not necessarily on a co-extrusion process must be resorted to.

In special cases, the core region of the profile according to the invention is made of a second plastic material, which differs from the plastic material of the surface layer (first plastic material). This then opens the possibility that a high-quality plastic material is used for the formation of the surface layer, while in the core area a much cheaper plastic material can be used. The same applies to the third plastic material.

The profiles of the invention are coated for special applications on the surface completely or at least partially with primers, primers and / or conductive paints. Thus, the profiles according to the invention can be prepared for aftertreatment processes such as the powder wet-paint or anodization process.

Use of the profiles according to the invention are in particular heat insulation profiles in the production of metal-plastic composite profiles.

The invention finally thermally insulated composite profiles, in particular for the production of windows, doors, facades or the like with an inner and an outer metal profile, which are connected via at least one inventive plastic profile as described above and held at a predetermined distance from each other.

Figur 1:

Eine schematische Schnittansicht durch ein erstes erfindungsgemäßes Kunststoffprofil;

Figur 2:

eine schematische Schnittansicht durch eine weitere Ausführungsform eines erfindungsgemäßen Kunststoffprofils;

Figur 3:

eine schematische Schnittansicht durch ein erfindungsgemäßes Hohlkammerkunststoffprofil;

Figur 4:

eine schematische Schnittansicht durch eine weitere Variante eines erfindungsgemäßen Hohlkammerkunststoffprofiles;

Figur 5

eine schematische Schnittansicht durch eine Variante des erfindungsgemäßen Hohlprofils gemäß Figur 4; und

Figur 6

eine schematische Schnittansicht durch eine Variante des erfindungsgemäßen Vollprofils gemäß Figur 2.

These and other advantages of the invention are explained in more detail below with reference to the drawings. They show in detail:

FIG. 1:

A schematic sectional view through a first inventive plastic profile;

FIG. 2:

a schematic sectional view through a further embodiment of a plastic profile according to the invention;

FIG. 3:

a schematic sectional view through an inventive hollow chamber plastic profile;

FIG. 4:

a schematic sectional view through a further variant of a hollow chamber plastic profile according to the invention;

FIG. 5

a schematic sectional view through a variant of the hollow profile according to the invention according to FIG. 4 ; and

FIG. 6

a schematic sectional view through a variant of the solid profile according to the invention FIG. 2 ,

FIG. 1 shows a plastic full profile provided with the reference numeral 10 with a surface layer 12 of a compact, non-porous first plastic material and a core portion 14 of a fine-pored second plastic material having a closed cell structure.

The profile itself is seen in cross section of a web 16 and a flange 18 together, which has a trapezoidal shape in cross section.

The flange 18 is formed so that it can be received by a complementary shaped groove of a metal profile part, which forms part of a composite profile. Usually, the profile 10 is arranged in its simplest form a mirror image of the flange 18 shown have a further flange, so that two metal profile parts held on the profile 10 at a distance and can be connected together.

In the in FIG. 1 In the embodiment shown, the thickness s _{1 of} the core area is 1.76 mm (measured on the web 16) and the wall thickness s _{2 of} the surface layer 12 is approximately the same on the entire profile 10, ie both in the web area 16 and in the flange area 18, and is for example 0.12 mm.

As a result, the closed-cell, fine-pored core region 14 extends into the trapezoidal structure of the flange 18.

This gives the profile in particular in its flange 18 a special ductility, which makes the knurling of the flange 18 receiving groove of the metal profile part positively noticeable by the knurled metal profile areas are easily pressed into the material of the flange 18 and thus easier a positive connection between the Metal profile part and the flange 18 of the profile 10 can be produced.

With such a structure of the profile 10 can be achieved with respect to a solid profile of the same material as the surface layer 12, a significant weight reduction at a possibly insignificant loss of stiffness.

From the values of various mechanical parameters listed in Tables I and II, the particular advantages of the structure according to the invention of the hollow profiles can be read in detail. The values apply to a solid profile according to Fig. 1 made of polyamide 66 having a short glass fiber content of 25% by weight. The comparative profile has the same outer dimensions, but is constructed throughout from the compact, non-porous plastic material as the surface layer 12 of the inventive profile 10. The values given are for profiles in the moisture balance (23 ° C and 50% humidity).

The pore size of the cells in the core region of the profiles according to the invention is in the range of about 0.02 to 0.05 mm.

The transverse stiffness factor is given per mm web height h, the weight per meter for a web with a web height of approx. 20 mm h.

Liquid CO _{2 was} used to form the core region.

Table I shows clearly that in the profile according to the invention a weight reduction by 28% can be achieved without the transverse stiffness suffers appreciably. Only a decrease of 6.8% is observed. <b> Table I </ b> example 1 Comparative example Core area 14 (porous) + - Thickness s ₁ mm 1.76 - WLZ λ ₁ W / m * K 0.14 - E-module E ₁ MPa 2700 - Density ρ ₁ g / cm ³ 0.90 - Surface layer 16 (compact) + Complete profile Thickness s ₂ mm 0.12 2.00 WLZ λ ₂ W / m * K 0.32 0.32 E-module E ₂ MPa 3000 3000 Density ρ ₂ g / cm ³ 1.32 1.32 Overall profile 10 total thickness mm 2.00 2.00 Thermal bridge factor s * λ mm * W / m * K 0.32 0.64 Transverse bending stiffness E * I MPa * mm ⁴ 1864 2000 Meter weight g / m 38.0 52.8

Table II shows with reference to Examples 2 to 4, that at a slight increase (instead of 2.00 mm: 2.50 mm) of the total thickness with the inventive profile a significant increase in the transverse stiffness factor can be achieved (> 100%), the profile always still a lower weight per meter compared to the conventional profile of the comparative example. <b> Table II </ b> Example 2 Example 3 Example 4 Comparative example Core area 14 (porous) + + + - Thickness s ₁ mm 1.9 1.5 1.2 - WLZ λ ₁ W / m * K 0.14 0.10 0.05 - E-module E ₁ MPa 2700 2200 1500 - Density ρ ₁ g / cm ³ 0.90 0.60 0.30 - Surface layer 16 (compact) + + + Complete profile Thickness s ₂ mm 0.30 0.50 0.65 2.00 WLZ λ ₂ W / m * K 0,320 0,320 0,320 0,320 E-module E ₂ MPa 3000 3000 3000 3000 Density ρ ₂ g / cm ³ 1.32 1.32 1.32 1.32 Overall profile 10 total thickness mm 2.50 2.50 2.53 2.00 Thermal bridge factor s * λ mm * W / m * K 0.46 0.47 0.48 0.64 Transverse bending stiffness E * I MPa * mm ⁴ 4205 4181 4190 2000 Meter weight g / m 50.0 44.4 41.5 52.8

FIG. 2 shows a variant of the embodiment in FIG. 1 Here, a profile 20 is presented, which in addition to a surface layer 22 has a fine-pored and closed cell core region 24. Again, it is a so-called solid material, with respect to the embodiment of FIG. 1 the core region extends only into the region of the web 26, but not into the flange region 28. The weight reduction observed in this profile is not quite as great as that in the FIG. 1 , and the improved ductility in the flange portion 28 is omitted here also compared to the profile according to FIG. 1 ,

FIG. 3 shows a hollow chamber plastic profile 30 according to the invention with a compact surface layer 32 and a fine-pored, closed-cell core region 34. The cavity of the hollow profile 30 is divided by a web 36, wherein the core region 34 extends into the web 36 inside. However, the core area does not form the inner surface 38 of the hollow profile, but this is formed by a compact material of the first plastic material, as well as the (outer) surface layer 32. This results in partial areas of the profile a kind of sandwich structure with parallel outer surface layer 32, core region layer 34 and inner Surface layer 38.

Again, the profile again has a web portion 40, to which a flange 42 connects at the free end.

A variant of in FIG. 3 shown hollow chamber profile is in the embodiment of FIG. 4 before, in which the profile 44 is formed by a surface layer 46 of a compact non-porous plastic material and a fine-pored, closed-cell core region 48, which now directly adjacent to the cavity of the hollow profile 44. This cavity is in turn subdivided by an inner web 50, which in this embodiment is made entirely of the material of the core region 48.

FIG. 5 represents a variant of the embodiment of FIG. 4 wherein the profile 52 according to the invention, similar to the profile 30 of FIG. 3 , the core portion 54 enclosed between the outer compact, non-porous surface layer 56 and a compact inner surface layer 58. The core region 54 extends as in FIG FIG. 4 in the area of the flange 59. Again, in some areas, as related to FIG. 3 described sandwich structures before.

FIG. 6 Finally, shows a profile according to the invention 60 with a surface layer 62 and a core portion 64, wherein the structure of the profile in a web 66 and a flange 68 divides. The fine-pored core region does not extend into the region of the flange 68. The increased ductility that is found in such embodiments (see, for example, embodiment of the US Pat FIG. 1 ) can also be achieved in this variant, characterized in that on a surface region of the surface layer 62, the part of the flange 68 is a fine-pored coating 70 provides. Here are similar advantages to those associated with FIG. 1 are described.

Claims (23)

1. Solid or hollow-chamber plastics profile, in particular, for tensile, bending and/or pressure loads, characterized by a surface layer of a compact, non-porous first plastics material and a core region having a fine-pored, closed-cell cellular structure of a second plastics material, the cellular structure in the core region having an average cell size ranging from 0.005 to 0.15 mm.
2. Profile as defined in claim 1, characterized in that the profile has a plurality of hollow chambers.
3. Profile as defined in claim 1 or 2, characterized in that the first and/or the second plastics material contains reinforcing materials, fillers, modifiers and/or additives.
4. Profile as defined in any one of claims 1 to 3, characterized in that the first and second plastics materials are of the same type.
5. Profile as defined in any one of claims 1 to 4, characterized in that the profile has one or more flanges moulded thereon, which have a fine-pored coating on at least areas of their surface.
6. Profile as defined in any one of claims 1 to 5, characterized in that the average cell size of the cellular structure in the core region ranges, on average, from 0.02 to 0.05 mm (diameter).
7. Profile as defined in any one of the preceding claims, characterized in that the density of the material forming the core region is up to 60 % less than that of its starting material.
8. Profile as defined in any one of the preceding claims, characterized in that the first and the second plastics materials are a thermoplastic, duroplastic or elastomeric plastics material or mixtures thereof.
9. Profile as defined in any one of the preceding claims, characterized in that the surface of the profiles is coated completely or in areas thereof with primers, adhesive lacquers and/or conductive lacquers.
10. Use of a profile as defined in any one of claims 1 to 9 as a heat-insulating profile in the production of composite profiles.
11. Heat-insulated composite profile, in particular, for the production of windows, doors, facade elements or the like, having an inner metal profile and an outer metal profile, which are joined to and kept at a specified distance from each other by at least one profile as defined in any one of claims 1 to 9.
12. Heat-insulated composite profile, in particular, for the production of windows, doors, facade elements or the like, having an inner metal profile and an outer metal profile, which are joined to and kept at a specified distance from each other by at least one plastics profile, the plastics profile being configured as a hollow-chamber plastics profile, characterized by a surface layer of a compact, non-porous first plastics material, a core region having a fine-pored, closed-cell cellular structure of a second plastics material, and an inner surface layer defining the hollow chamber and made of a compact, non-porous third plastics material.
13. Profile as defined in claim 12, characterized in that the core region is completely enclosed by the surface layer and the inner surface layer defining the hollow chamber.
14. Profile as defined in claim 12 or 13, characterized in that the surface layer, the core region and the inner surface layer form a sandwich structure at least in sections of the profile.
15. Profile as defined in any one of claims 12 to 14, characterized in that the profile has a plurality of hollow chambers.
16. Profile as defined in any one of claims 12 to 15, characterized in that the first, second and/or third plastics material contains reinforcing materials, fillers, modifiers and/or additives.
17. Profile as defined in any one of claims 12 to 16, characterized in that at least two of the first, second and third plastics materials are of the same type.
18. Profile as defined in any one of claims 12 to 17, characterized in that the plastics profile has one or more flanges moulded thereon, which have a fine-pored coating on at least areas of their surface.
19. Profile as defined in any one of claims 12 to 18, characterized in that the average cell size of the cellular structure in the core region ranges, on average, from 0.02 to 0.05 mm (diameter).
20. Profile as defined in any one of claims 12 to 19, characterized in that the density of the material forming the core region is up to 60 % less than that of its starting material.
21. Profile as defined in any one of claims 12 to 20, characterized in that the first, second and third plastics materials are a thermoplastic, duroplastic or elastomeric plastics material or mixtures thereof.
22. Profile as defined in any one of claims 12 to 21, characterized in that the third plastics material of the inner surface and the first plastics material used in the surface layer are the same.
23. Profile as defined in any one of claims 12 to 22, characterized in that the surface of the plastics profile is coated completely or in areas thereof with primers, adhesive lacquers and/or conductive lacquers.

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