PVC profile systems covered with aluminium profiles or foils by gluing directly on the PVC base profile

Abstract

 The invention consists of a profile system "Direct Glued ALU-PVC profile systems" and on this basis a system of elements of joinery from PVC plated with aluminum, which can be produced using the classical technological process. Thus:
1. To achieve this system used aluminum sheets rolls in case of rolling, strips of sheet with length and width appropriate for bending or extruded profile. These aluminum profiles can be done considering the configuration and dimension of any PVC profile system - see for example Figure 3.
2. Clipping system used in the past has been replaced by a permanent connection by bonding the aluminum to the PVC profile as in Figure 4, 5, 6, resulting in a composite profile, PVC with outer surface covered with aluminum as in the example in Figure 2.
3. Then, this profile is processed in order to obtain the joinery elements by the classic method:
a) cutting, reinforcing;
b) drilling, milling;
c) welding;
d) cleaning corners.


In addition, before welding, the milling process of the aluminum profile according to Figures 7, 8, 9 has to be done.
I mention that all the details are given as a general and illustrative concept and the method can be applied to all PVC systems.
Have been done tests on the following systems: Bruegmann - Salamander 73 mm, Salamander Blue Evolution 92 mm 74 mm Gealan S8000, S3000 Gealan 63 mm, 76 mm Profine Trocal, barter 88 mm.
In the same way the process can be performed on any type or brand of PVC profiles.

Description

Technical Field: external thermal insulated PVC joinery

Background Art

[0001] Historically, aluminum plating was originally used to cover the elements of old joinery with a new layer of painted aluminum that offers a high resistance and long life, giving also a new look to the joinery.

[0002] Based on these, considering the needs and technical possibilities, several methods of aluminum application were developed in time.

[0003] One common method of application of aluminum, is the one which uses plastic clamps, glued or fixed with screws directly on the PVC profiles. The properly cut aluminum profiles are directly fixed on this support by the simply clipping process.

[0004] Another method, which is more difficult to be applied on the already mounted old joinery due to plaster applied, is to clip the aluminum profile directly to joinery items frame/sash - the aluminum profile is clamped on the entire length of the frame/sash, on both sides of the profile.

[0005] There are other methods all based on various clamping systems, hence the trade name of these covers is "Alu-Clip".

[0006] Patents relative: EP 1022423 A2, EP 1877640 B1, EP 1243738 A3, DE 3844195 C2

Deficiencies of old systems

[0007] 

• In general all known methods require a contribution of great hand work. Basically the joinery is executed in a traditional classic way, then, each component of the aluminum plates is cut, and all operations are hand-made, requiring high qualified work and not always with the best results.
• Also, aesthetically, the corners alignment of aluminum profiles is very difficult to be perfectly made, thus, lacking many times in aspect due to small joinery dimensional deviations.

[0008] An improvement of the aesthetic can be made by welding together the aluminum profiles corners followed by a grinding process of the remaining burrs for perfect flatness. It also requires great efforts and highly qualified work.

• This method cannot be used for doors that have an outside opening, because the needed direct contact between the hinge and the PVC profile cannot be accomplished due to the distance between the aluminum cover and PVC profile. The contact is only through the aluminum profile used in the plating, which is poorly bound to the basic profile.
• Also, the contribution of the aluminum profile, to strengthen the joinery is null, due to the poor contact between the aluminum and PVC profile

[0009] Technical issues that I intend to solve by the present invention is to develop a method of applying, on any kind of profile systems, aluminum plates cover, so as to result a profile system in which the process of achieving further joinery is as easy as possible and significantly easier than a traditional way. Therefore, through the method applied one will obtain:

A. Reduction of costs for the aluminum plates production process. The extruded aluminum profile, having a very complex production process, is replaced in our proposal with a simple strip of aluminum sheet, which is then profiled by rolling. Considering the shape of the base profile, it is not excluded the usage of the extruded profiles also.

B. I solved the problem of applying the aluminum on rounded profile - not flat - which is in general difficult to obtain by known methods.

C. I solved the perfect connection at the corners, for a flawless aesthetic appearance.

D. I solved the problem of plating the doors with external opening. In the invention, directly glued aluminum plate, makes one body with the profile.

E. Through the invented method I succeeded to increase the mechanical parameters of the PVC profiles: moments of inertia in both directions transverse and in-depth I_x si I_y, implicitly increasing the bending rigidity and load capacity of the profiles. This results in a lower requirement of reinforcement inside the profile, from here resulting also a decrease of the thermal conductivity of the profile systems.

The invention itself:

[0010] I have detailed three ways, technological processes, to realize this invention "Direct Glued ALU-PVC profile systems", that is PVC profile systems with aluminum cover by direct gluing. Also, other methods of bonding can be used that will lead to the compliance of the presented technical details.

METHOD I

[0011] For carrying out the invention I used aluminum rolled sheets with the thickness between 1 and 2 mm and different widths considering each type of PVC profile to be plated.

[0012] Step 1. The plate cut to proper width, passes through a rolling system, resulting the shape of the profile that needs to be plated according to Figure 3. The example of Bruegmann Salamander profile system is given here, but following the same process, the method can be applied to any PVC systems.

[0013] This stage of aluminum profiling, can be replaced by simply bending the aluminum sheet to the needed angle, previously cut to the correct size.

[0014] Also, one can use extruded aluminum profile at the required dimensions.

[0015] Step 2. The aluminum profile resulted after Step1 is painted in the traditional way.

[0016] Step 3. This step represents the effective process of bonding the aluminum profile resulted after step 1 and 2. After this step one will have one body profile. Figure 4 shows an exemplified application in case of the frame using profile system Salamander Evolution Blue 92 mm. Initially, the surface of the PVC profile (6) is covered by a layer of adhesive (2). The adhesive layer may be applied also on the aluminum profile. Aluminum profile (1'), becoming (1), is applied on the classical PVC profile (6) through bonding. The two profiles are combined by pressing them with a roller (16) or with another pressing system, in order to perfectly bond them, resulting a single body entity.

[0017] The result is a PVC profile covered with a glued aluminum plate, a multilayer profile with a part of the characteristics of the classic aluminum cover systems and even more fulfils the characteristics, points A and E from the technical description.

METHOD II

[0018] The steps 1 and 2 are the same as in method I.

[0019] Step 3. The process of bonding shown in Figure 5 is carried out in this case applying a double-sided adhesive tape (2') on the aluminum profile (1'), becoming (1), or as an alternative directly to PVC profile (6). These are pressed to each other through rolling (16) or by another pressing method.

[0020] The results is almost similar like in the case of method 1.

METHOD III

[0021] The presented method uses an aluminum foil with the width according to the profile dimensions, relatively thin from 0.12 mm to a maximum of 0.5 mm, pre-painted - usually electrostatically painted.

[0022] The process is show in Figure 8.

[0023] This aluminum foil (1') is passed through a lubricant-dosing device applying the proper adhesive.

[0024] The mechanism applies the adhesive to the inner face of the aluminum foil, the one that comes into contact with the PVC profile - area (2), using a roller system. Immediately aluminum foil is applied to the flat surface of PVC profile using a roller (16) and then using different rollers (17), which can have various configurations considering the PVC profile model, it is modelled and pressed on the profile surface.

[0025] This type of profile has, as the others, the qualities described from A to D in the technical details of the document, except point E.

[0026] The disadvantage of this method is that using a thin foil of aluminum the purpose is purely decorative and it does not lead to the increase of the mechanical properties of the resulted profile.

[0027] The advantage of this method is that in the process can be used the usual devices for applying classic PVC foil, with small changes to be made to the rolling system.

[0028] For the construction of joinery with the profiles obtained through the three methods presented above, it has to be followed by the normal construction process of PVC items: cutting, mechanical reinforcement + milling/drilling, welding, cleaning corners, assembly.

[0029] A special case is the step of the welding process. Given the fact that aluminum profile completely covers on the outside the PVC profile, in order to make the classic hot welding process, where some parts of PVC profiles (2-3 mm) are melted at temperatures between 180 and 320 degrees Celsius and then joined by pressing, it takes a first step of frame milling of aluminum applied in this area, which can prevent melting and then joining.

[0030] This additional operation of milling the aluminum profile is done using a copy machine or CNC milling machine (numerically controlled machine) Oxyz 3-axis, as shown in Figures 7, 8, 9.

[0031] Therefore excess is removed from aluminum in the welding zone (19) on the portion required in depth direction and in direction of the axis Oy, usually 1.5 - 3.5 mm (depending on the profile system and welding type) and on a depth equal to the thickness of the aluminum, on the opposite direction of the axis Oz. The miller follows the entire outline of the aluminum profile, on the 2 axes Ox and Oz.

[0032] Also it enters a certain depth, usually 1/3-1/4 out of the thickness of the PVC profile wall (20) in order to avoid the extra layer that come out of the melting of PVC during normal welding process.

[0033] In Figure 7 is the additional technological process where it is seen the mill (18) which, by moving on the axes Ox, Oy, Oz, remove zones (19) from the aluminum and (20) from PVC profile. Figure 8 represents (C), a detailed area of Figure 7.

[0034] As an alternative of milling the profile, in case the wall of the profile is very thin, it is shown in Figure 9 and Figure 10, where the area (19), removed from the aluminum is supplemented with a gap (hole) (21) in order to make space for the excess of the melted PVC in the welding process. Also, the edge which results from profiling, helps to stop the excess to exit on the surface.

[0035] Related to the increase of the load capacity of the profiles, plated according to the invented method, it leads, according to calculations, to a decrease in requirements of steel reinforcement between 5-30% for classic PVC or classic plated PVC profiles.

Claims

1. Method of disposal of the aluminum plate by bonding directly on PVC profile "Direct Glued ALU-PVC profile systems" regardless of the type of bonding used in Method I, II, III, or not described in the present invention, namely whatever type or brand of PVC profile used.

2. The method claimed in section 1 applied in any of the stages of production of joinery.

3. The PVC profiles "Direct Glued ALU-PVC profile systems" with plated aluminum, for any type of PVC profile (Ex: 5-frame, 6 - sash), an aluminum plate over 0.5 mm thick (Ex: 1- frame, 4 -sash) or aluminum foil tape 0.12-0.5 mm, an adhesive layer (2,3) or double adhesive tape (2'), joined together to form a single body entity, according to claim 1 or 2, regardless of the type or brand of PVC profile used.

4. Method for milling the aluminum from the plated PVC profile claimed in 2, in the region of the joint (19) before welding. Milling is done with mill (18), which moves in the direction of Oxyz axes, so that the entire outline of the aluminum profile will be cut in depth and in-depth welding excess throughout its thickness.

5. The milling method of plated aluminum according to claim 4, in addition to creating an area (21) where it is accumulated the excess resulting from the welding process, regardless of the formed area.

6. The joinery doors - windows - curtain walls, etc. - resulted from the materials claimed in section 3, that were obtained through the methods described and claimed in section 1 and 2.

Drawing