Profile for building openings

Abstract

 A profile (4, 5) for building openings (1), comprising a core portion (6) and a cover portion (7), wherein the core portion (6) and the cover portion (7) are made of plastic-containing materials, said materials having different properties and a method of making the same.

Description

[0001] The present invention relates to a profile for building openings, wherein the profile comprises a core portion and a cover portion and a method for making the same.

Technical field

[0002] Different kinds of profiles are known for use in building openings such as windows, doors, gates and the like. Profiles such as batten, beading, list, mould, reglet, and fillet for use in building openings, such as a window or a muntin bar, is known from US 4,437,284. Profiles for use as a window bar or a muntin bar are often extruded in plastic as plastic profiles or they may be of solid wood.

[0003] Profiles in plastic are often slightly flexible, which may result in a unintended curved window bar when placed across the window glass inside the frame due to the lack of support across the frame. This unintended curved window bar may be a result of the effect of the sun or that the window bar is not able to hold its own weight. Thus, the profiles are, in some cases, supplemented with a rod of steel or wood inside the profile for supporting the hollow profile when mounted across a window frame. The supporting of the profile by a rod of steel or wood is expensive and requires a subsequent process of mounting the rod inside the hollow profile. Furthermore, machining of the profile, such as shaving, shaping, threading etc., requires a change in tools, some tools for shaping in plastic and other tools for shaping in wood or steel.

[0004] Furthermore, sometimes during the manufacture of the profile or by a subsequent use of the profile it has been desired to paint these plastic profiles on one or both sides of the profile. By painting a plastic profile the property of the profile has been shown to change when the painted plastic profile is exposed to the heat of the sun. During this heating of the profile the temperature of the painted profile may be increased by up to 35° more than non-painted profiles. Thus, the painting of the profile results in the cross-sectional shape of the profile being smoothed out due to the heat generated by the sun.

[0005] Additionally, when mounting a hollow profile extruded in plastic the placement of a piece of wood in each end of the profiles is often used for connecting the profiles via the wood pieces, for instance, to the frame of a window. This kind of mounting is time-consuming and expensive and the fact that these pieces might be released from the profile makes this kind of fastening even more unwanted.

[0006] Thus, there is a need for a profile which has a somewhat stable shape and which may be exposed to normal weather conditions without reducing the life of the material of the profile.

[0007] Furthermore, there is a need for a profile which may be painted intentionally or unintentionally without reducing the life of the profile and without effecting the shape of the profile.

Summary of the invention

[0008] An object of the present invention is to overcome wholly or partly the above disadvantages and drawbacks of the prior art. More specifically, it is an object to provide a profile for building openings which profiles has a cross section shape which is maintained substantially constant regardless the weather and regardless whether the profile is subsequently painted.

[0009] An additional object of the present invention is to provide a profile which shape in the longitudinally direction of the profile is substantially constant over time and regardless the changes in temperature.

[0010] Furthermore, it is an object of the present invention to extend the life of the profile when exposed to all kinds of weather conditions.

[0011] The above objects, together with numerous other objects, advantages and features, which will become evident from the below description, are accomplished by a solution in accordance with the present invention by a profile for building openings, comprising a core portion and a cover portion, wherein the core portion and the cover portion are made of plastic-containing materials, said materials having different properties. This two-part profile enables that the core portion and the cover portion may have different properties, i.e. that the cover portion may be made of a UV-resistant material and the core portion may be given rigidity property. Likewise, the core portion may have a property of heat expansion in the length of the core portion less than that of the cover portion, so that the core portion is able to counteract the expansion in the length of the cover portion, and thereby prevent the profile from changing shape, when heated.

[0012] Furthermore, the profile may be connected to a frame of the window or the like building openings via the core portion without the mounting of additional means, such as a piece of wood, in a subsequent process before mounting the profiles to e.g. a frame of a window.

[0013] Advantageously, according to the invention the plastic-containing material of the core portion and the plastic-containing material of the cover portion has chemically compatible components which gives a chemical connection instead of e.g. an mechanically connection between the core portion and the cover portion. For which reason gluing of a core piece for connecting the profile to for instance the frame of the window is no longer necessary.

[0014] Expediently, according to the invention, the chemically compatible components are of the plastic compatible materials or the same plastic material, such as PVC (polyvinyl chloride), PP (polypropylene), PE (polyethylene), ABS (acrylonitrile butadiene styrene), ASA (acrylnitrile styrene acrylate), PC (polycarbonate) or the like. This enables a more successive and strong connection between the core portion and the cover portion. An example of compatible plastic materials are PVC and ASA/ABS.

[0015] In another preferred embodiment according to the invention the material of the cover portion is a foamed plastic which has the advantage that the weight of the profile is decreased in relation to profiles made of non-foamed plastic.

[0016] Additionally, the core portion is made of a material which has a coefficient of expansion lower than that of the cover portion according to another embodiment of the present invention. It is hereby obtained that the core portion during changes in the surroundings, such as changes in temperature, content of moisture in the air etc. substantially maintains its shape. Due to the fact that the core portion is connected at its surface surrounded by the cover portion to the inside of the cover portion, the core portion is thereby able to prevent or at least hinder the cover portion from changing shape considerably, which makes the outer shape of the profile very dimensionally stable during such changes in the surroundings.

[0017] Furthermore, the material of the core portion may comprise cellulose, wood, flax, linen, fibre glass, hemp or the like according to an embodiment of the present invention. It is hereby obtained that the profile is so rigid as to hold up its own weight when mounted across a building opening such as in a frame of a window. And further that the core portion of the profile has a lower coefficient of expansion compared to that of wood, especially in regards to moisture absorption and swelling.

[0018] In practice it has been found that a window bar of mere PVC keeps its shape until the temperatures of 65-70°C, but this temperature range is increased when using a core portion of plastic-containing material with fibres of wood.

[0019] Additionally, a core portion of this plastic composite with cellulose or the like in combination with a cover portion of foamed plastic enables almost the same machining possibilities as for mere wood which makes the mounting of the profile in building opening much easier, e.g. mounting the profile in a frame of a window. Consequently, it is no longer necessary to change tools when working with a profile which has both a foamed plastic-containing material and a plastic composite containing wood. Furthermore, the tools used for machining known profiles of wood can be reuse to shape these inventive profiles.

[0020] Furthermore, a profile with a core portion of plastic composite with e.g. wood fibres complimented with a cover portion of foamed plastic has overcome a additional problem which is that profiles of plastic composite materials containing fibres changes in colour during time and especially from the effect of the sun. Additionally, the foamed plastic will provide a smooth surface compared to a profile of mere plastic composite containing fibres composite due to the potential raising of the fibres on the surface of the profile.

[0021] According to the present invention the material of the core portion is more rigid than mere plastic which makes the profile more rigid and is especially useful in window bars to be mounted across the frame of window.

[0022] In another preferred embodiment according to the invention the core portion and/or the cover portion is of a material resistant to moisture. Hereby is obtained that the profiles may be used in both indoors and outdoors building openings without resulting in an expansion of the shape of the profile, more especially resulting in an expansion of the length of the profile.

[0023] Furthermore, in an additional preferred embodiment according to the invention the core portion and/or the cover portion is dimensionally stable at temperatures from -20°C to 90°C. By obtaining dimensionally stability within this range of temperatures it is obtained that the profiles may placed in all building openings regardless the weather conditions of the this building opening without expansion of the frame in which the profile may be placed within. This further enables a more homogeneous production of profiles for use under different weather conditions, indoors as well as outdoors, and thereby results in a less expensive profile production.

[0024] Advantageously, in another preferred embodiment according to the invention the cover portion is of a UV-resistant material or comprises UV-stabilizers. This UV-resistant ability makes the profile less effected by the sun and will therefore increase the life of the plastic-containing material of the profile.

[0025] In another embodiment of the present invention a layer is situated between the core portion and the cover portion. This layer may be of a different plastic-containing material than the materials of the core and the cover portion. It is hereby obtained to place a third property into the profile or if two plastic-containing materials are less chemically compatible the layer may be used as a gluing layer.

[0026] The invention further comprises a method of producing a profile for building openings as claimed in any one of the claims 1-11, comprising in the steps to increase the temperature in a first plastic-containing material, to supply a second plastic-containing material with an expanding agent, so that the second plastic-containing material subsequently will foam, to foam the second plastic-containing material by increasing the temperature in the material, to supply the first plastic-containing material with cellulose or wood, to extrude the first plastic-containing material to form a core portion and to extrude the second plastic-containing material to form a cover portion.

[0027] Additionally, the extrusion of the first plastic-containing material to form a cover portion and the second plastic-containing material to form a core portion may be done substantially simultaneously according to invention.

[0028] Furthermore, in the method according to the invention the step to increase the temperature in the first plastic-containing material is carried out by heating or by processing the material in the worm of an extruder.

Description of the Drawings

[0029] The invention and its many advantages will be described in more detail below with reference to the accompanying schematic drawings, which for the purpose of illustration show some non-limiting embodiments and in which

[0030] Fig. 1 shows a window with different profiles according to some embodiments of the invention.

[0031] Fig. 2 shows a cross-section of the window in Fig. 1 taken along line A-A.

[0032] Fig. 2a is an enlarged part of the cross-section shown in Fig. 2 showing a profile in the form of a fillet.

[0033] Fig. 2b is an enlarged part of the cross-section shown in Fig. 2 showing a profile in the form of a window bar.

[0034] Fig. 3 shows a perspective of an end of a profile according to one embodiment of the invention.

[0035] All the figures are highly schematically and not necessarily to scale, and they show only parts which are necessary in order to elucidate the invention, other parts have been omitted or merely suggested.

Description of the Preferred Embodiments

[0036] Fig. 1 shows a window 1 comprising a window frame 2 surrounding window glass 3, and further comprising the profiles 4, 5 in the form of window bar 4 and fillets 5. The window bar 4 are placed within the window frame 2 for the reason of fencing the window glass 3 or just as a decoration of the window 1. The fillets 5 are pressed against the window glass 3 towards the window frame 2 for fencing the glass 3 and for the reason of sealing the window 1.

[0037] Fig. 2 shows a cross-section taken along line A-A in Fig. 1 in which cross-section the area of the two profiles 4, 5 are enlarged into two separate views Fig. 2a and 2b. The cross-section in Fig. 2 reveals that the fillets 5 hinders the window glass 3 from falling away from the window frame 2 due to the fact that the window glass 3 rest against the abutment surfaces 9, when the fillets 5 presses the window glass 3 against the abutment surfaces 9.

[0038] The enlarged cross section in Fig. 2a shows a cross-section of a profile 5 according to one embodiment of the present invention in which the profile 5 is used as a fillet 5 for hindering a window glass 3 from falling out of the window frame 2. As can be seen in Fig. 2a, the profile 4, 5 according to this embodiment comprises a core portion 6 and cover portion 7 made of materials which differs from each others. The material of the core portion 6 are in this embodiment made of substantially rigid materials, such as plastic and cellulose or plastic and wood or the like materials. The cover portion 7 is made of a foamed material comprising a plastic, which is compatible with the plastic-containing material of the core portion 6, so that the materials of the core portion 6 and the cover portion 7 are chemically combinable. This combinability makes the core portion 6 stay in place in relation to the cover portion 7 especially in the longitudinally direction of the profile, but helps also the cover portion to maintain its shape, when the profile is heated.

[0039] Furthermore, both the foamed material of the cover portion 7 and the cellulose and plastic containing material of the core portion 6 enables shaving of shape of the profile 4, 5 and/or threading in the material of the profile 4, 5.

[0040] The shape of the cross section of the core portion 6 shown in Fig. 2a is different from a round shape and corresponds substantially to the outer contour of the cross section of the fillet 5. The cover portion 7 is arragned around the core portion 6. By having a shape that corresponds substantially to the shape of outer shape of the profile 4, 5 the core portion 6 can support the shape of the profile 4, 5, so that the profile 4, 5 will maintain its shape regardless the weather conditions the profile is exposed to.

[0041] Furthermore, due to the fact that the shape of the cross section of the core portion 6, shown in Fig. 2a, is different from a round shape the core portion 6 will be kept from rotating in relation to the cover portion 7.

[0042] Additionally, the fillet 5 in Fig. 2a is shown with a weather strip 8 or a sealing strip 8, which strip in this embodiment is mechanically fastened to the fillet 5. The weather strip 8 may as well be fasten by using glue or tape in a subsequent operation or the strip 8 may be co-extruded together with the profile or it may be melted together with the newly extruded and warm profile 4, 5.

[0043] In Fig. 2b the profile 4, 5 is shown as a bar 4 which is placed outside a window glass 3. The bar 4 has a core portion 6 and a cover portion 7 which likewise the above shown fillet 5 is made of materials which differs from each others, but the materials comprises at least one chemically combinable component, such as different types of plastics. The cross section of the core portion 6 of the bar 4 has substantially a shape that corresponds to the shape of the cross section of the outer shape of the bar 4. By this shape correspondence the core portion 6 is able to support the cover portion 7 and thereby the outer contour of the bar 4 regardless the weather conditions of the window 1, so that the bar 4 during use has the same shape as a newly made bar 4.

[0044] Furthermore, the material of the core portion 6 comprises cellulose, so that the core portion 6 is more rigid than the cover portion 7. This enables that the bar 4 can maintain its shape in the longitudinally direction across the window glass 3 in non-supported parts of the bar 4 and refrain these parts from bending downwards due to the weight of the bar 4 and when heated by the sun.

[0045] In Fig. 3 a profile 4, 5 according to the invention is shown as a cross section of a bar 4 with a core portion 6 and a cover portion 7. It is evident that the cross section shape of the core portion 6 differs from a round shape and that the outer contour of the bar corresponds to this cross section shape of the core portion 7, i.e. the cover portion 7 is here shown as a substantially uniform layer. Furthermore, the material of the cover portion 7 is made of a foamed material which enables shaving of the outer contour of the bar 4. In this embodiment of the inventive profile the core portion and the cover portion is co-extruded together.

[0046] The bar 4 and the fillets 5 according to this invention is easily fasten to the frame 2 of the window 1 due to the core portion 6 is made of a pulpwood and plastic composite which has approximately the same fastening abilities as wood.

[0047] Additionally, in another embodiment of the present invention the cross section shape of the core portion 6 of the profile 4, 5 may assume all kinds of shape and therefore also shapes which is different from the shown shapes in Figs. 1-3.

[0048] By the term building openings is meant windows 1, doors, gates or the like. Furthermore, by the term window bar is also meant window muntin, cross bar, bar, glazing bar, transom and mullion.

[0049] Additionally, by the term foamed plastic is meant cellular plastic, i.e. plastic which has been exposed to an effervescent substance, such as expanding agent, blowing agent, fermenting agent or the like. The expanding agent may as well be a gas such as Freon, carbon dioxide or the like, or it may be water added to form bubbles in the material. Likewise, by the term cellulose is also meant pulpwood, wood, flax, linen, hemp and the like material.

[0050] The profile 4, 5 according to the invention can be made by use of a method comprising in the steps to supply a second plastic-containing material with an expanding agent, such as sodium-bicarbonate, azo-dicarbonate-amid or the like, so that the second plastic-containing material subsequently will foam, to foam the second plastic-containing material by increasing the temperature in the material, to increase the temperature in a first plastic-containing material, to supply the first plastic-containing material with cellulose or wood, to extrude the first plastic-containing material into a core portion 6 and to extrude the second plastic-containing material into a cover portion 7.

[0051] In a preferred method according to the invention the profile is made by the step to co-extrude the first and the second plastic-containing material simultaneously to form a core portion 6 surrounded by a cover portion 7.

[0052] The final cross section shape of the profile 4, 5 is given by the inside of a mould which cools the profile 4, 5.

[0053] The temperature is preferably increased to a range of 150-200°C depending on the plastic-containing material.

[0054] In another preferred method of producing a profile 4, 5 a weather strip 8 or a sealing strip 8 is co-extruded together with the profile 4, 5, but this weather strip 8 may as well be connected to the profile 4, 5 by melting the strip onto the profile 4, 5 when this is still warm or by using tape or glue. Furthermore, the weather strip 8 may also be added to the profile 4, 5 by mechanical means, e.g. the strip 8 may be barbed and pressed into a groove in the profile 4, 5, which groove may also be barbed to increase the friction between the profile 4, 5 and the strip 8.

[0055] Additionally, the method of producing a profile 4, 5 may subsequently comprise the step to paint the profile 4, 5 with a colour on one side or both sides of the profile 4, 5.

[0056] According to the scope of the invention the profiles may also be used for making up a window frame, door frame and/or a casement of the building opening, the dimensions of the profile just has to be increased or adapted accordingly. Likewise, the profiles according to the invention may be used as skirting boards, dressings of a door, jamb lining of a door, thresholds and the like.

[0057] Furthermore, the profiles according to the present invention may within the scope of the invention be used for surrounding and/or fencing the window glass and/or mirror glass of vehicles and the like. Furthermore, the profiles may likewise be used for framing filter devices, screens, displays, paintings, tables and the like.

[0058] Additionally, it should be noted that a window comprising profiles according to the present invention has a lower coefficient of thermal transmittance (U-value) than that of windows not comprising such inventive profiles.

Claims

1. A profile (4, 5) for building openings (1), comprising a core portion (6) and a cover portion (7), wherein the core portion (6) and the cover portion (7) are made of plastic-containing materials, said materials having different properties.

2. A profile (4, 5) as claimed in claim 1, wherein the plastic-containing material of the core portion (6) and the plastic-containing material of the cover portion (7) have chemically compatible components.

3. A profile (4, 5) as claimed in claim 1 or 2, wherein the chemically compatible components are of the plastic compatible materials or of the same plastic material, such as PVC (polyvinyl chloride), PP (polypropylene), PE (polyethylene), ABS (acrylonitrile butadiene styrene), ASA (acrylnitrile styrene acrylate), PC (polycarbonate) or the like.

4. A profile (4, 5) as claimed in any one of claims 1-3, wherein the material of the cover portion (7) is a foamed plastic.

5. A profile (4, 5) as claimed in any one of claims 1-4, wherein the core portion (6) is made of a material which has a coefficient of heat expansion lower than that of the cover portion (7).

6. A profile (4, 5) as claimed in any one of claims 1-5, wherein the material of the core portion (6) comprises cellulose, wood, flax, linen, fibre glass or the like.

7. A profile (4, 5) as claimed in any one of claims 1-6, wherein the material of the core portion (6) is more rigid than mere plastic.

8. A profile (4, 5) as claimed in any one of claims 1-7, wherein the core portion (6) and/or the cover portion (7) is of a material resistant to moisture.

9. A profile (4, 5) as claimed in any one of claims 1-8, wherein the core portion (6) and/or the cover portion (7) is dimensionally stable at temperatures from -20°C to 90°C.

10. A profile (4, 5) as claimed in any one of claims 1-9, wherein the cover portion (7) is of a UV-resistant material or comprises UV-stabilizers.

11. A profile (4, 5) as claimed in any one of claims 1-10, wherein a layer is arranged between the core portion (6) and the cover portion (7).

12. A method of producing a profile (4, 5) for building openings as claimed in any one of claims 1-11, comprising in the steps

- to increase the temperature in a first plastic-containing material,

- to supply a second plastic-containing material with an expanding agent, so that the second plastic-containing material subsequently will foam,

- to foam the second plastic-containing material by increasing the temperature in the material,

- to supply the first plastic-containing material with cellulose or wood,

- to extrude the first plastic-containing material to form a core portion (6) and

- to extrude the second plastic-containing material to form a cover portion (7).

13. A method as claimed in claim 12, wherein the extrusion of the first plastic-containing material to form a cover portion (7) and of the second plastic-containing material to form a core portion (6) occur substantially simultaneously.

14. A method as claimed in claim 12 or 13, wherein the step to increase the temperature in the first plastic-containing material is carried out by heating.

Drawing