Method and device for welding at least two profiled sections for window or door frames or leaves

Abstract

A method and a device (10) for welding at least two profiled sections (1) for window or door frames or leaves uses a heating unit (4) introduced between the profiled sections (2, 3) to be joined. At least two heating elements (5, 6) of the heating unit melt the profiled section ends (2, 3) at the end surfaces to be joined. In order to chamfer, in particular remove, a profiled section edge layer (20) of the profiled section ends (2, 3) along the layer surfaces (12, 13) thereof, at least one tool, in particular at least one cutting blade (7, 8), is arranged on the heating elements (5, 6) and is moved such that the material (9) to be melted is displaced into the profiled section interior (11) or into the interior (12) of the profiled section chambers (13). A compression device compresses the profiled section ends (2, 3).

Claims

1. A method for welding at least two profiles for window or door frames and casements or leaves, the method comprising the following steps: providing the at least two profiles, wherein the at least two profiles comprise a first profile having a first profile end and a second profile having a second profile end; positioning a heating unit having at least two heating elements including a first heating element and a second element between the first and second profile ends; chamfering each of the first and second profile ends with at least one tool arranged on each of the first heating element and the second heating element to form a chamfer on each of the first and second profile ends; delivering the first and second profile ends having the chamfer into contact with the first and second heating elements; melting respective joining surfaces of the first and second profile ends with the first and second heating elements, which contact with the respective joining surfaces; moving the first and second heating elements to displace melt material formed during melting into an interior of the first and second profiles; removing the first and second heating elements from between the first and second profile ends; and swaging the first and second profile ends against one another so that the first and second profiles are joined together at the respective joining surfaces.

2. The method according to claim 1, wherein moving the first and second heating elements comprises relative movement between the first and second heating elements in a joining plane (F) substantially parallel to the respective joining surfaces.

3. The method according to claim 1, wherein the first and second heating elements are movable vertically towards and away from one another and/or horizontally towards and away from the first and second profiles.

4. The method according to claim 1, wherein each of the first and second heating elements has at least two heating surfaces.

5. The method according to claim 3, wherein the horizontal and/or the vertical movement of each of the first and second heating elements is independently controlled.

6. The method according to claim 1, wherein the at least one tool arranged on each of the first and second heating elements is a cutting blade having a plurality of cutting edges, and wherein the cutting blade on one of the first or second heating element is configured to operate as lower cutting blade on the first and second profile ends and the cutting blade on the other of the first or second heating element is configured to operate as an upper cutting blade on the first and second profile ends.

7. The method according to claim 1, wherein the chamfer on each of the first and second profile ends has an ablation depth in a miter direction that is at least as deep as a melt end path during the melting process, and wherein the melt end path is an endpoint depth of melting into each of the first and second profile ends in the miter direction.

8. The method according to claim 7, wherein the ablation depth defines a separating region line extending perpendicular to the miter direction, and a joint endpoint line marks the region on each of the first and second profile ends up to which each of the first and second profile ends is swaged during swaging, and wherein either: the separating region line coincides with either: a melt endpoint line marking the melt end path or the joint endpoint line, or the separating region line lies between the melt endpoint line and the joint endpoint line.

9. The method according to claim 6, wherein each cutting blade is heated by the heating unit.

10. The method according to claim 1, wherein the first and second heating elements are fitted with coated, corrugated, and/or toothed heating plates.

Description

DESCRIPTION OF THE DRAWINGS

(1) The following are shown schematically:

(2) FIG. 1 a perspective view of the apparatus according to the invention,

(3) FIG. 2 a sectional view of the apparatus according to the invention in a first position before the ablation of a profile edge layer,

(4) FIG. 3 a sectional view of the apparatus according to FIG. 2 in a further position during the ablation of the profile edge layer,

(5) FIG. 4 a detailed view according to FIG. 3,

(6) FIG. 5 a sectional view of the apparatus according to FIG. 1 in a further position at the beginning of the melting process,

(7) FIG. 6 a sectional view of the apparatus according to FIG. 5 in a further position at the end of the melting process,

(8) FIG. 7 a detailed view according to FIG. 6,

(9) FIG. 8 a sectional view of the apparatus according to FIG. 5 in a further position at the end of the melting process and opened table supports,

(10) FIG. 9 a sectional view of the apparatus according to FIG. 1 with a molding shortly before the start of the swaging process,

(11) FIG. 10 a sectional view of the apparatus according to FIG. 9 with the swaging process already started,

(12) FIG. 11 a sectional view of the apparatus according to FIG. 9 in a further position at the end of the swaging process,

(13) FIG. 12 different configurations of a groove,

(14) FIG. 13 a sectional view of the apparatus according to FIG. 2 in two further positions during the ablation of the profile edge layer, and

(15) FIG. 14 a perspective view of a further embodiment of the apparatus according to the invention according to FIG. 1 with the molding.

(16) Identical or identically functioning components are provided with reference numerals based on multiple embodiments in the subsequently depicted figures of the illustrations in order to improve readability.

DETAILED DESCRIPTION

(17) The present invention relates to a method and an apparatus 10 in the form of a welding machine for welding at least two profile parts or profiles 1 for window or door frames and casements or leaves. An overview of the apparatus 10 is shown in FIG. 1 as well as in FIG. 14, in which the profiles 1 to be joined to one another can be seen, which face one another with their joining surfaces 26, 27. The respective method steps are generally carried out on both profiles 1 simultaneously.

(18) In the present case, the profile 1 is a profile element 1 made of thermoplastic material, for example PVC, for the production of a window casement or door leaf. The profile 1 is designed as an extruded profile having a plurality of profile walls 28 running parallel, transversely, and at an angle to one another, whose outermost border forms the profile edge 29. The profile 1 comprises, on the one hand, the lower 17 and the upper visible surface 18 and, on the other hand, functional surfaces which form the outer surfaces of the profile 1. The visible surfaces 17, 18 are the surfaces visible to the outside in the fully assembled state of the window or door. The functional surfaces are those surfaces that are required for the various functions of the window casement, such as the overlap that seals the window against the window frame, the support surface that supports a window pane inserted in the window, and other functional surfaces on which, for example, pane seals are arranged.

(19) The profile 1 is first cut to the profile blank length, which is longer by the so-called burn-off than the final dimension required for the joined profile 1.

(20) In particular, in FIG. 1 and FIG. 14, the so-called positioning step, which can be part of the method according to the invention, is shown schematically. In this positioning step, the respective profile 1 is pressed with its joining surface 26, 27 against a stop surface (not shown) of a profile stop in order to align the joining surface 26, 27 with the stop surface. Both profiles 1 can be positioned simultaneously if they are pressed against the stop surfaces of the profile stop in order to align the respective joining surfaces 26, 27 with respect to the profile stop and thus with a heating unit 4 and with one another.

(21) After the profile part 1 is aligned with the profile stop, the profile 1 is clamped tightly on the profile support 30 such that no significant movement between the profile 1 and the profile support 30 can take place in the following steps.

(22) According to FIG. 1 and FIG. 14, at least one limiting element in the form of a limiting blade 15 is arranged on the profile support 30, which rests on the outer surface of the profile part 1, here on the lower visible surface 17 hidden in FIG. 2, and in doing so touches the joining surface 26, 27 of the Profile 1 adjacent.

(23) The apparatus 10 also has a heating unit 4 with at least two heating elements 5, 6, which in the present case are designed as heat reflectors, as shown in FIGS. 1 to 8. The two heating elements 5, 6 of the heating unit 4 can be moved and positioned horizontally and/or vertically by means of a servo motor 25; in particular, the two heating elements 5, 6 can be moved towards one another and/or in the direction from the inner to the outer corner and/or from the outer to the inner corner of the joined profiles 1, as can also be seen in FIG. 1. The horizontal and/or vertical movement of each heating element 5, 6 can be controlled independently of one another.

(24) A relative movement is carried out between each heating element 5, 6 and at least one joining surface 26, 27 in a joining plane F, which is substantially parallel to the at least one joining surface 26, 27, as illustrated in particular in FIG. 2.

(25) Each heating element 5, 6 has at least two heating plates or heating surfaces 23, 24, which are each associated with a joining surface 26, 27 of a profile end 2, 3 to be joined. The heating elements 5, 6 can be fitted with coated, preferably Teflon-coated, corrugated, or toothed heating surfaces 23, 24, in particular on both sides.

(26) As can be seen from FIGS. 1 to 4 and 14, in particular the corresponding detailed views, a tool is arranged on each heating element 5, 6, in the present case in the form of a cutting blade 7, 8 with preferably a plurality of cutting edges 16, wherein the lower visible surface 17 of the profile end 2, 3 has an assigned lower cutting blade 7 and the upper visible surface 18 has an assigned upper cutting blade 8. The cutting blades 7, 8 can be heated in particular by means of the heating unit 4, which is the case in the present embodiment of the invention.

(27) The visible surfaces 17, 18 are processed on their respective profile edge layer 20 by means of these cutting blades 7, 8, i.e. the profile ends 2, 3 are preferably chamfered at least in the melt path along their visible surfaces 17, 18, and a chamfer is produced towards the visible surface 17, 18. The outer profile edge layer 20 of the profile 1 is thus removed. Through this ablation of material in the visible surface region of the profile 1, the material of the outermost profile edge layer 20 in the region of the visible surface 17, 18, which is harmful to the corner strength, is removed. The profile edge layer 20 can also contain the protective film or the decorative film of the profile 1 itself. FIG. 2 shows the profile edge layer 20 in a detailed view.

(28) In addition, tests have shown that, even in the case of profiles 1 without any protective and/or decorative films, particles or components are contained on or in the profile edge layer 20 in the region of the visible surface 17, 18, which are extremely damaging to the corner strength of the joined profiles 1, for example, necessary means of PVC profile extrusion, impurities from storage and/or transport, or the like. In addition, experience shows that profile surfaces cut immediately before joining achieve significantly higher corner strength values than unprocessed surfaces.

(29) For this reason, it is advantageous to remove only the outer profile edge layer 20 of the profile 1. As a result, as much material as possible remains on the profile 1 and is therefore not ablated, so that the strength of the corners is not impaired.

(30) As can be seen from FIG. 13.1, the ablation depth 19 of the ablated coating or profile edge layer 20 on the profile 1 seen in the miter direction 21, i.e. the separating region line 32, preferably has the same dimensions as at least the melt end path 31 during the melting process. Furthermore, other ablation depths 19 and thus other separating region lines 32, for example between the melt endpoint line 31 and the joint endpoint line 33, are also conceivable, as can be seen from FIG. 13.2.

(31) As FIGS. 1 to 8 further illustrate, the heating unit 4 with the heating elements 5, 6 is positioned between the profile ends 2, 3 of the profiles 1 to be joined.

(32) According to FIGS. 3 and 4, in particular the corresponding detailed views, the aforementioned chamfering of the profile ends 2, 3 takes place along their visible surfaces 17, 18 by means of at least one tool arranged on the heating elements 5, 6 of the heating unit 4, in particular by means of the at least one cutting blade 7, 8.

(33) The result can be seen in FIG. 5, in particular from the detailed view there, according to which the profile ends 2, 3 are chamfered, in particular at least up to the melt end path 31. As a result, the geometry of the mechanically removed chip is preferably designed as a slope, i.e. a chamfer. On the one hand, this has the advantage that less material is ablated, which leads to an increase in corner strength, because more material volume is available. On the other hand, the direction of flow of the melt material 9 in the melting process is better guided in the necessary direction, i.e. into the profile interior 11 or the interior 12 of the profile chambers 13.

(34) After the chamfering, the profile ends 2, 3 to be joined together are delivered onto the heating unit 4, as is shown in FIGS. 5 to 8.

(35) FIG. 5 shows the start, FIGS. 6 and 7 show the end of the melting, and FIG. 8 shows the end of the melting with the profile supports 30 already open. During melting, the joining surface 26, 27 of the profile 1 is pressed against the heating surfaces 23, 24 of the heating unit 4 in order to melt the profile 1 on its joining surface 26, 27 at the front. For this purpose, the respective profile supports 30 can be moved in the direction of the heating unit 4, which has been moved between the joining surfaces 26, 27 of the profile parts 1 after the profile stop has been removed.

(36) According to FIGS. 5 to 8, it is substantial in the present invention that the heating unit 4 is divided into a plurality of parts. This is because the heating elements 5, 6 move in such a way that the melt material 9 is displaced into the profile interior 11 or into the interior 12 of the profile chambers 13 of the profiles 1. In this way, the melt material 9 can be displaced inwards into the profile chambers 13 in a controlled manner from the visible surfaces 17, 18. Within the scope of the invention, it is also conceivable that the heating element 4 is also formed of more than two parts, in order to direct even more melt material 9 into the interior chambers 12, for example from front to back, from back to front, from top to bottom, and from bottom to top.

(37) The melting process includes the melting of the profile 1 up to the melt endpoint, the post-heating, i.e. staying at the melt endpoint so as to generate deep heat, i.e. heating the material to be swaged. In the present case, both are combined to form the melting process, which is used to move the melt material 9 into the profile interior 11 or into the interior 12 of the profile chamber 13.

(38) Furthermore, the melt end path or the melt endpoint line 31 is shown in FIGS. 3 and 5, which marks the region up to which the heating unit 4 penetrates into the material of the profile 1 during the melting process. The material melted in the method escapes as excess melt or melt material 9 and is shifted into the interior of the profile 11 in a controlled manner by the movements of the heat reflector. FIG. 3 shows the cutting process and FIG. 5 shows the introduction of the heating unit 4.

(39) Furthermore, the separating region line 32 between the melt end path or the melt endpoint line 31 and the joint endpoint line 33 is shown in FIG. 3. The separating region line 32 indicates up to which point the profile edge layer 20 is ablation. The joint endpoint line 33 characterizes the region up to which the profile 1 is swaged on its profile wall 28 during the subsequent joining step. The method can also be modified in such a manner that the separating region line 32 and the melt endpoint line 31 coincide, or that the joint endpoint line 33 and the separating region line 32 coincide. However, the arrangement shown in FIG. 2 is preferred, in which the separating region line 32 is provided closer to the melt endpoint line 31 than to the joint endpoint line 33.

(40) Furthermore, in FIGS. 9, 10, and 11 a molding 14 acting as a post-processing tool is shown. As mentioned, the melt material 9 produced by the partial melting is displaced into the profile interior 11 by the movements of the heat reflector. The molding 14 is intended to prevent heated material from being pushed outwards when the profiles 1 are swaged. The molding 14 can also be seen in FIG. 14.

(41) First, there is a controlled shift of the excess melt or melt material 9 into the interior of the profile 11 using the multi-part heating unit 4. Here, the heating elements 5, 6 are moved in such a way that the melt material 9 is displaced into the profile interior 11 or into the interior 12 of the profile chambers 13 of the profile 1.

(42) After the melt material 9 has been pushed inwards, which is shown in FIGS. 9 to 12, the two profile parts 1 can be processed by means of a molding 14. In the present example, a two-stage post-processing takes place, in which, during the swaging process of the respective profile edge 29, a direction of movement directed inwards onto the joining surface 26, 27 is impressed, so that during the subsequent joining, a V-groove results between the profile parts 1 in the region of the weld. FIG. 12 with its detailed views shows different configurations of this V-groove.

(43) During the shaping and/or displacement of the melt material 9 by means of the molding 14, the profile ends 2, 3 can be swaged against one another in order to join the profiles 1 to one another. It is also conceivable for the profile ends 2, 3 to be swaged against one another without reshaping and/or displacing the melt material 9 by means of a molding 14.

(44) FIG. 9 shows the apparatus shortly before the start of the swaging process, FIG. 10 shows an intermediate position, and FIG. 11 shows the end of the swaging process.

(45) FIG. 10, in particular the detailed view, makes it clear that the contour, i.e. the bevels of the molding 14, touch the limiting blade 15, in particular its contour, i.e. the bevels, and thus terminate the path of the melt material 9 to the outside. The design of the V-groove of the connection can be adjusted via the position, more precisely the distance A, which can be adjusted independently of the profile supports 30, of the limiting blade 15 at the swaging end, as can be seen from FIG. 12. The larger the distance A at the end of the swaging process, the larger the gap between the limiting blades 15. In this way, the molding 14 is pushed less over the bevels of the limiting blade 15 outside the connection, and the molding 14 can remain deeper in the joint plane F, so that a larger V-groove can be realized, as can be seen from FIG. 12.3. With a distance A of zero between the limiting blades 15, the molding 14 is pushed out completely from the profile 1 and no V-groove occurs, as shown in FIG. 12.1. FIG. 12.2 shows an intermediate position.

(46) FIG. 9 shows the position shortly before the start of joining or swaging of the profiles 1. The molding 14 stands above or below the visible surface 17, 18 and is pushed up/down by the swaging process via the bevels or the undercut of the limiting blade 15. Thus, the region for the melt material 9 is already blocked from the outside by the molding 14, and no melt material 9 can penetrate to the outside due to the joining process.

(47) Two measures ensure that the molten material cannot exit at the visible surface 17, 18 during joining/swaging, one measure in the melting process and one measure in the swaging process, respectively.

(48) In the melting process, melt material 9 is moved in a controlled manner into the interior 12 of the profile chambers 13 by the heating unit 4 and its movements during the melting process. In order to ensure that no impurities from the region of the visible surfaces 17, 18 can get into the melt material 9, material and thus possible impurities are ablated from the surface of the profile 1 in the joining region.

(49) Furthermore, during the swaging process, the contour of the molding 14 can shape the heated material between the melting point and the joint endpoint, and at the same time it can prevent the melt material 9 from escaping to the outside due to the form-fit of the bevel of the molding 14 with the bevels of the limiting blade 15 and, depending on the limiting blade position, contribute to the shaping at the swaging end.

(50) The limiting blade 15 can be guided under spring tension in the direction of the joining surface 26, 27 in order to form the narrowest possible gap between the heating surface 23, 24 and the separating edge during the melting step. The function of the limiting blade 15 can also be supplemented by the molding 14, which minimizes the escaping of the melt material 9 outwards in the melting step. At the same time, the molding 14 can terminate with the joining plane F.

(51) Protective films present on the visible surfaces 17, 18, which are not shown here for the sake of simplicity, can remain on the profile 1 without prior processing and do not impair the aesthetics and the mechanical strength of the joint created according to the invention, or do so only insignificantly.

LIST OF REFERENCE NUMERALS

(52) 1 Profile 2 Profile end 3 Profile end 4 Heating unit 5 Heating element 6 Heating element 7 Tool/cutting blade 8 Tool/cutting blade 9 Melt material 10 Apparatus 11 Profile interior 12 Interior of the profile chamber 13 Profile chamber 14 Molding 15 Limiting blade 16 Cutting edges 17 Lower visible surface 18 Upper visible surface 19 Ablation depth 20 Profile edge layer 21 Miter direction 23 Heating surface 24 Heating surface 25 Servomotor 26 Joining surface 27 Joining surface 28 Profile wall 29 Profile edge 30 Profile support 31 Melt end path and melt endpoint line 32 Separating region line 33 Joint endpoint line F Joining plane A Distance between the limiting blades