US 20060283554 A1
Vibratory welded connections are formed between first and second members of thermoplastic material by interposing a junction piece of similar material and vibrating the junction piece at high speed while pressing the first and second members in a controlled manner against opposite sides of the junction piece. Friction created by the vibration generates heat which melts a small amount of material at the engaging surfaces which upon cooling provides a strong welded joint having minimal flash. Entire frame systems such as window frames can be fabricated by an apparatus system which forms a friction welded joint between adjacent ends of the frame members. Furthermore the frame can be fabricated around a panel such as a glazing panel. The welded connections formed by the system do not mar the finish of the frame members and produce no unsightly flash bead requiring subsequent machining steps for its removal.
1. A frame comprising a plurality of elongate frame members, adjacent ends of pairs of said members being interconnected through an interposed junction piece, wherein said frame members and said junction piece are each composed at least in part of a thermoplastic resin, wherein each said junction piece is secured to a pair of adjacent frame members by vibratory welded bonds on opposite sides of said junction piece, and wherein said junction piece has a planar flange that extends at an angle with respect to each said frame member.
2. The frame of
3. The frame of
4. The frame of
5. The frame of
6. The frame of
7. The frame of
8. The frame of
9. The frame of
10. The frame of
11. The frame of
12. The frame of
13. The frame of
14. The frame of
15. The frame of
16. The frame of
17. The frame of
18. The frame of
19. The frame of
20. The frame of
21. The frame of
22. The frame of
This application claims the benefit of U.S. patent application Ser. No. 10/473,677, and is a divisional thereof. U.S. patent application Ser. No. 10/473,677 was filed on Sep. 30, 2003 as a National Phase application of PCT/CA02/00842, which was filed on Jun. 7, 2002 claiming priority from Canadian Patent Application Serial Number 2,349,795, filed on Jun. 7, 2001.
This invention relates generally to assembly methods for thermoplastic components and more particularly to methods and apparatus for manufacturing window and door frames using vibration welding techniques.
At present, plastic window and door frames are typically assembled from polyvinyl chloride (PVC) extruded profiles using hot plate welding technology. Typically, the corner welding process involves pressing the mitered cut ends of two profiles against a Teflon-coated heated metal plate. After the thermoplastic PVC material has melted, the heated metal plate is removed and the two ends are then pressured against each other forming a hermetically sealed welded bond. Typically, in manufacturing a four sided frame assembly either one-head, two-head or four-head welding equipment is used. For four-head welding equipment, the complete frame is assembled in one operation and, taking into account the time required for frame set-up, profile loading, corner welding, cool down and frame unloading, the total cycle time is about two minutes.
As well as being a comparatively slow process, a further drawback of hot plate welding is that a large quantity of plastic flash is created at the weld line and this plastic flash has to be mechanically removed through a process that can involve cutting, shaving and routing operations. Generally, the equipment required for flash removal is complex and expensive and the process can also damage any surface coatings applied to the extruded profiles. In addition because the plastic flash material is contaminated during the welding process, the removed waste material cannot be recycled and the contaminated material can also effect the final weld strength. Finally to order consistently achieve a square right angled square corner, the equipment incorporates elaborate and complex mechanical support systems.
Vibration welding is one commonly used method for welding together the flat surfaced end walls of two thermoplastic components. As described in U.S. Pat. No. 4,352,711, the typical vibration welding process involves one component being held firmly in place in a stationary bottom fixture while a second component is firmly held in place in a moveable top fixture. By applying pressure and moving the top fixture very rapidly, heat is generated through surface friction, in a very short period of time, that melts the two contact surfaces of components that are to be welded together and thus in addition to a short cycle time, a further key advantage of vibration welding is that minimum flash is generated so that the need for mechanical flash removal can be substantially reduced. Generally, the two plastic component parts are injection molded and this allows for flash dams and other features to be incorporated into the components. As a result, even with the limited flash that is generated, its movement and location is controlled so that it is not visually obtrusive or unsightly.
Various efforts have been made in the past to use vibration welding techniques for plastic frame assembly but without commercial success. In U.S. Pat. No. 5,902,657, issued to Hanson et al, two alternative processes are described that are specifically developed for manufacturing window and door frames. One technique uses an apparatus similar to a conventional hot plate welder where a vibratory metal plate rapidly moves back forth between the ends of two profiles. To create a welded joint, the metal plate is then removed and the two profiles are pressed against each other. As described, there are some technical issues with this process because unlike conventional hot plate welding, only a thin surface layer is heated and as a result, when the vibratory metal plate is moved away, the small amount of surface plastic material that has been melted is either removed and/or rapidly cools down so that when the two profiles are finally pressed together the welded bond formed between the two profiles is poor.
There are also some technical concerns with the second alternative process described in U.S. Pat. No. 5,902,657. With this method for a four-sided frame, two opposite sides are held fixed in position while the other two sides are moveable. The moveable sides are held in fixtures that are connected to four vibratory heads that are located at profile corner ends when directly welding together two hollow thin wall profiles. Because the vibratory head moves back and forth very rapidly, it is very difficult to accurately control the final position of the vibratory head and so consequently the thin profile walls are not correctly aligned and this results in reduced corner weld strength as well as an uneven joint line which is visually noticeable.
With vibration welding, there is typically a minimum zone of disturbance at the weld line. However, for glass fiber re-enforced plastics as described in U.S. Pat. No. 5,874,146 by Kagan et al, higher structural strengths can be achieved with a wide weld zone that allows for some of the glass fibers to orient away from the flow direction and to cross the weld interface.
The invention provides a method for forming a vibratory welded connection between first and second members and a junction piece where said members and said junction piece are composed at least in part of thermoplastic resin material,
said method comprising providing a vibratory head; engaging said junction piece in a fixture connected to said vibratory head; mounting said first and second members in fixtures that are independent of said vibratory head; creating an engagement force between each of said first and second members with a respective opposite side of said junction piece; maintaining said engagement forces while vibrating said junction piece by means of said vibratory head at a frequency of from 50 to 500 Hz to create friction generated heat to melt material on the ends of said members and on each respective opposite side of said junction piece, such melted material upon cooling forming a weld between said junction piece and said members; and where said engagement forces between said first and second framing members and said junction piece are applied separately from the operation of the vibratory head.
Preferably the engagement forces provide even pressure on each side of the junction piece. The engagement forces desirably are varied in the duration of the welding step such that after the desired degree of melting of the materials of the engaging faces has been achieved, each engagement force is reduced to a level wherein the melted material remains molten in position between the ends of the members and the junction piece.
Preferably the junction piece has a planar flange that extends at an angle with respect to each of the members, the junction piece incorporating a removable tab that is an extension of the planar flange. The tab is held in the fixture connected to the vibratory head, and after the welding step has been completed it is removed. The tab preferably has a geometric shape that is held in the fixture in an insert hole with a similar geometric shape, e.g. T-shaped, the junction piece being held firmly in position by means of metal spring attachments or the like. Alternatively, the junction piece can incorporate insert holes for engagement by insert pins on the fixture to secure the junction piece in position.
For a particular application, the vibratory corner welding process is controlled by adjusting the duration of the operation of the vibratory head for a specified amplitude, frequency, and engagement force.
From another aspect the invention provides Apparatus for forming a vibratory welded connection between end faces of first and second frame members and a junction piece, and where said frame members and said junction piece are composed at least in part of a thermoplastic material, said apparatus comprising:
a) a vibratory head including a drive for vibrating said head in a predetermined plane at an amplitude or at least 0.4 mm and at a frequency of from 50 to 500 Hz;
b) opposed first and second fixtures each having clamping structure for securing thereon a respective one of said first and second frame members and where said first and second fixtures support said first and second frame members for movement independently of said vibratory head;
c) a third fixture for holding the junction piece in a balanced way and typically in a central location on said vibratory head, said junction piece having a planar part that is aligned perpendicularly to said predetermined plane;
d) guide structure for guiding relative movement between said frame members and said junction piece in directions parallel to said predetermined plane and perpendicular to said planar part and to said end faces to facilitate engagement between opposite sides of said junction piece and said first and second frame members respectively;
e) pressure actuators coupled to first and second fixtures to provide an engagement force between opposite sides of said junction piece and said first and second members; and
f) a control system to regulate the operation of the vibration corner welding apparatus.
Preferably there are adjustment mechanisms associated with each pressure actuator whereby the engagement force provided by each pressure actuator is independently adjustable. In this way, a variable force of engagement can be provided through the duration of the welding step.
The third fixture which holds the junction piece is preferably located so that the planar flange of the junction piece is balanced and positioned typically in a central location, with the first and second fixtures being movable independently of this third fixture.
The invention also contemplates a system for interconnecting a series of elongate frame members to form a closed frame. In this system adjacent ends of adjoining frame members are engaged by use of the aforesaid apparatus. The frame member can be a rectangular frame, a set of apparatuses aforesaid being provided at each of the four corners of the frame.
The framing members need not be assembled at right angles, but can in fact be connected at any selected angle in the range 90° to 15°. The angles of adjoining frame members with respect to the junction piece can also be different. Nor is it essential that the framing members be straight, but on the contrary, one or more of the framing members may be longitudinally curved.
The system for interconnecting the frame members can be used to assemble those members around an inner panel prior to the frame members being welded together to form a complete assembly with the panel. The panel can be of any desired composition such as a sheet of glass or rigid plastics material, an insulating glazing unit, a multi-cavity sheet extrusion, or the like.
The invention further provides a frame comprising a plurality of elongate frame members, adjacent ends of pairs of said members being interconnected through an interposed junction piece, wherein said frame members and said junction piece are each composed at least in part of a thermoplastic resin, wherein each said junction piece is secured to a pair of adjacent frame members by vibratory welded bonds on opposite sides of said junction piece, and wherein said junction piece has a planar flange that extends at an angle with respect to each said frame member.
Preferably each hollow profile has a peripheral wall that provides a surface for welding to the planar flange. The hollow profile of the frame members can be subdivided into two or more cavities.
Preferably the planar flange has a thickness in the range of 2 mm to 12 mm and preferably 3 mm to 6 mm.
The flat surfaces of the planar flange may incorporate a textured surface finish to improve the build-up of friction generated heat.
The frame members are preferably composed of glass fiber reinforced thermoplastic material, such as polyvinyl chloride. The frame members can have decorative coatings or finishes incorporated on their outer surfaces.
The junction piece may preferably carry integral legs that extend from opposite sides of the planar flange, the legs being sized to engage longitudinally within the hollow interiors of the adjacent frame members. The integral legs of the junction piece may incorporate each an integral spring centering device. Furthermore the hollow frame profile members can be fixed to the legs of the junction pieces by ultrasonic spot welding at locations spaced from the planar flange.
Preferably the ends of the framing profiles are miter cut to provide the desired corner angle of the frame, e.g. a miter cut at 45° to provide a 90° corner. The miter cut ends of the framing profiles may be formed with a so-called dado cut (open sided groove) and a pressure plate can be applied on the miter cut ends of the front face of the framing profile during the welding process to prevent the appearance of this front face being marred by any welding flash.
The junction piece can incorporate devices such as traps, grooves or welding beads for locating or receiving plastic flash generated during the vibratory welding process.
There are three preferred applications for the vibration corner welding process, namely: (i) where frame members are assembled around an insulating glass unit and where silicone sealant is applied in gaps between the assembled frame and the insulating glass unit; (ii) where glazing sheets are directly adhered to the sides of a frame assembly using silicone sealant, and (iii) where an assembled frame is located between spaced glazing sheets.
The following is a description by way of example of certain embodiments of the present invention, reference being made to the accompanying drawings, in which:
Referring to the drawings
In North America, the structural performance of thermoplastic corner welds are evaluated according to the North American Fenestration Standard (NAFS-1) test procedure. As shown in
As described in detail with reference to
A removable tab 49 that forms an extension of the planar flange 48 is located on the outer side back of the junction piece 47. During the vibration welding process, this tab 49 is firmly held in a holding fixture 50 linked to the vibratory head 52 of the special vibration welding apparatus 51 as described in
A corner test sample was fabricated using the same hollow square profile PVC extrusions with 30 percent glass content as the samples that had been previously made using conventional hot plate welding equipment. The profile samples were welded to the planar flange using the special vibration welding techniques but unlike the hot plate welded test samples, these vibration welded test samples passed the NAFS-1 Thermoplastic Corner Weld test procedure.
As shown in
1. Vibratory Head
A linear vibratory head 52 that incorporates a top plate 53 which vibrates back and forth very rapidly in a predetermined plane.
2. Junction Piece Holding Fixture
A junction piece holding fixture 50 is directly attached to the top plate 53 and firmly holds the planar flange junction piece 48 in position.
3. Moveable Framing Fixtures
Two moveable framing fixtures 55 and 56 incorporate clamping devices 60 that firmly hold the framing profiles in position. The movement of the framing fixtures 55 and 56 is operated through a variety of means including: electrical servo motors, pneumatic and hydraulic devices.
4. Control Systems
A control system 46 that regulates the various operating parameters of the vibration welding apparatus including: weld time, hold time, joint pressure, amplitude, frequency and voltage. The control system is located in a protective housing and is linked to an operator interface 64.
5. Machine Frame
A machine frame 65 provides the structure that supports the other components.
The vibratory head 53 can move in either a linear or orbital manner. With linear vibration welding, the vibratory head moves back and forth very rapidly in a predetermined plane. While with orbital vibration, the vibratory head continuously rotates in a circular operation. As a continuous process, orbital vibration offers some major advantages including: reduced time, less energy, less weld amplitude, reduced clearance and better flash control. At present, orbital vibration is somewhat less reliable because the continuous circular motion is driven by an electrical motor and so only linear vibration welding is illustrated in the following figures. However, it can be appreciated by those skilled-in-the-art that orbital vibration welding can also be substituted for many of these corner welding applications and specifically, the process offers advantages where a planar flange junction piece is used.
Flat plate metal sheets 54 are bolted to the top surface of the machine frame 65 but this top working surface is separated apart from the vibratory head 52 so that a minimum of vibratory movement is transferred to the machine frame 65. Moveable profile fixtures 55 and 56 are supported on guide rails 57 directly attached to the top table plate 54 and these fixtures hold the framing profiles extrusions 32 and 33 in position. The moveable profile fixtures 55 and 56 move over the vibratory head 52 but there is no direct contact except where the framing profiles 32 and 33 contact the junction piece 47. The moveable fixtures also allow for the miter cut ends 34 of the framing profiles 32 and 33 to be positioned parallel to the planar flange 48 of the junction piece 47.
Each moveable profile fixture 55 and 56 consists of a horizontal flat plate 58, a support member 59 that is attached to the horizontal plate 58 and a clamping fixture 60 that firmly holds the profiles 32 and 33 against the support member 59. A front clamp 60 is positioned adjacent to the side edge 61 of the flat plate 58 and to ensure that the profile 33 is firmly held in position, the miter cut profiles 32 and 33 only extend 2 or 3 mm beyond the side edge 61. It is also important that both the profiles extend the same distance from the two clamping fixtures.
To provide for a right angled joint connection (i.e. 90°), the vertical support members 59 are positioned at a 45° angle to side edge 61. However for special framing shapes, the angular position a of the support member 59 can be adjusted as required by means of a pivot point 62 and an attachment device 63. A fixed holding fixture 50 for the junction piece 47 is located so that the planar flange of the junction piece is in a balanced central position. The holding fixture 50 which is directly attached to the top plate 53 of the vibratory head 52, firmly holds the removable tab 49 of the junction piece 47 in position.
In operation, friction heat is generated at the two joint interfaces between the parallel surfaces of the miter cut ends 34 of the framing profiles 32 and 33 and the planar flange 48 of the junction piece 47. By vibrating the junction piece 47 back and forth and by simultaneously pressuring the framing profiles 31 and 32 against the planar flange 48 of the junction piece 47, friction heat is generated at the two joint interfaces. When a molten state is reached at the two joint interfaces 66 and 67, the vibration is stopped and the perpendicular pressure P is then maintained briefly while the molten plastic solidifies to form two welded joints 66 and 67 on either side of the planar flange 48. In order to provide for even weld strength, essentially the same perpendicular engagement force has to be simultaneously applied to each side of the junction piece 47
In the vibration welding process, if excessive pressure is applied after the surface plastic has been melted, the melted plastic can be pushed away from the joint line resulting in a poor structural bond. By carefully controlling the engagement force or pressure of the framing profiles on the junction piece, this joint bond problem can be avoided. After the desired degree of melting of the materials at the joint line has been achieved, the engagement force is reduced to a level where the melted material remains molten in position between the ends of the framing profiles.
In friction welding glass fiber filled profiles, one of the reasons for reduced weld strength is that the glass fibers align along the weld line, perpendicular to the applied engagement force or pressure. This weld zone is typically very narrow varying from 40 to 100 microns. By carefully controlling and optimizing the welding parameters and particularly the applied pressure, a wide weld zone can be created so that some of the glass fibers are oriented away from the weld line and cross the weld interface. As a result, higher weld strengths can be achieved for the glass-fiber filled profiles.
Using the prototype corner welding apparatus, a series of experiments have been carried out and these experiments have shown that satisfactory structural welds can be achieved by optimizing the different welding parameters through quite a wide range of different parameter values. For example, maximum applied pressure can be reduced if amplitude is increased, or both maximum applied pressure and amplitude can be reduced if weld-time is increased. Particularly to reduce the amount of plastic flash that is produced, our experiments have also shown that is preferable to use a higher frequency and a lower amplitude. Generally, the different welding parameters can be varied through the following values although for each application, there is a need to establish a particular set of welding parameters.
Generally for a particular application, the vibratory corner welding process is controlled by the weld time that is determined for a specified weld amplitude, frequency and maximum applied pressure or engagement force. It should be noted that weld time is defined as the duration of the operation of the vibratory head.
Using the prototype single corner vibration corner equipment as described in
For simple corner web designs, the junction pieces can be die cut from plastic sheet material. Alternatively, the junction pieces can be injected molded and this has the advantage that various design features can be incorporated into the junction piece that essentially eliminate the need for plastic flash removal.
As shown in
For the vibration welding equipment shown in
To eliminate this need for special custom fixtures,
As shown in
Rather than incorporating flash traps and welding beads, an alternative method for controlling plastic flash as shown in
As shown in previous figures, the junction piece 47 consists of a planar flange 48 with a removable tab 49. For certain framing applications, this planar flange configuration does not provide for sufficient structural support and there is a need for additional corner re-enforcement. As shown in
As shown in
As shown in
One of the main advantages of using ultrasonic spot welding is that it is an assembly technique that joins two similar thermoplastic components at localized points with no preformed hole or energy director. In operation, the spot welding tips pass through the frame profile wall and the molten plastic displaced is shaped by a raised cavity in the tip (not shown) forming a neat, raised ring on the surface. Simultaneously, energy is released at the interface producing frictional heat. The tip then penetrates the corner key, displacing molten plastic material between the two surfaces and after the plastic has solidified, this forms a permanent structural bond between the framing profiles and the corner key legs.
Although frame assemblies can be manufactured using a single corner welder, it is more productive if two or more corners are welded simultaneously.
A first set of vibration welding heads 130 and 133 are attached to the first bridge support 124 that is fixed in position and a second set of vibration welding heads 131 and 132 are attached to the second moveable bridge support 125. Each set of vibration welders are operated by a electro servo motor driven ball screw that in combination with special control devices allow the vertical position of each head to be individually controlled so that in operation, all four heads can move up and down either simultaneously or independently towards a central horizontal datum line 154. After the four heads 130, 131. 132 and 133 have moved to their initial start location, the four framing profiles 134, 135, 136 and 137 are loaded into position as well as the four junction pieces 138,139,140 and 141.
In contrast to a conventional four point welder where all four corners are welded simultaneously, the preferred operating strategy for friction welding is a two stage process. As shown in
As shown in
Because the friction welding process is so fast (3 to 6 seconds), this two stage process does not significantly increase cycle time and compared with simultaneously welding all four corners, the key advantage is that the required movement and control of the heads is greatly simplified. For the four head welder, the controllers for the individual heads form part of a coordinated control system (not shown) that controls all four heads as well as the operation of the other mechanized components of the automated four point welder.
For a conventional four head, hot plate welder, the overall cycle time is about 2 minutes and this overall cycle time includes: profile loading, corner welding, cool down and frame unloading. In comparison, the estimated overall cycle time for the two-stage vibration welding process is less than 30 seconds and so this represents a significant increase in productivity. To further improve productivity, one option is to incorporate an automated mechanical feed (not shown) for installing the junction pieces in the corner holding fixtures.
As shown in
Although vibration corner can generally be used to join together extruded plastic profile extrusions, the improved assembly method offers particular advantages for fenestration applications. In addition to the production of conventional windows and doors, the improved assembly method provides for the development of new types of fenestration products. To illustrate the performance advantages of vibration corner welding, FIGS. 21 to 31 show three examples of these new types of fenestration products, namely: 1. composite channel window panels, 2. glass panel units and 3. sealed frame window panels.
Compared to the simple rectangular frame assemblies illustrated in previous figures, these new types of fenestration products incorporate complex profile shapes, but it should be noted that the basic component joint design does not change and the planar flange junction piece can be configured to correspond to the miter joint contour of these more complex profiles shapes.
With conventional hot plate welding, in order for the thin wall profile walls to be welded together at the corners, the framing profiles have to be essentially the same size and shape. However with vibration corner welding, by using a common corner web, different profile sizes and shapes can be structurally joined together. For example as shown in
It should be noted that when joining together different size profiles using friction corner welding, it is necessary for the two moveable framing fixtures to apply different engagement forces so that when taking into account the different profile sizes, essentially the same pressure is being applied on either side of the web.
Although the examples given in FIGS. 21 to 24 show examples of a window framing profile being assembled around an insulating glass unit, it can be appreciated by those skilled-in-the-art that the same production process can also be used to fabricate a wide range of frame-and-panel products including: picture frames; mirrors; partitions; shower doors and cupboard doors.
One option is for the corner web to only extend to the top profile wall 181 of the I-shaped cavity 178 and to incorporate a notch 182 in the miter cut corners of the framing profiles 176 and 177. As a result, while the bottom part of the profiles 183 is sealed and welded at the corners, the miter cut solid profile walls 184 only butt together. However because the vibration welding process can be closely controlled, the open gap 185 between the two miter cut profiles 176 and 177 can be kept to a minimum.
For insulating glass panels, the main advantage of using vibration corner welding is that there is a continuous, single wall barrier seal made from rigid thermoplastic material. As a result, the back face 192 of the spacer frame can incorporate a variety of profile features including attachment devices. In addition without damaging the integrity of the barrier seal, other thermoplastic parts (e.g. gas fill patches) can also be welded to the back face 192 of the spacer frame 186.
The perimeter frame 194 is assembled from glass-fiber filled, hollow thermoplastic profiles 197 which are joined and sealed at the corners using vibration corner welding. The thermoplastic profiles incorporate glass fiber fill and as previously noted this provides for increased strength and rigidity as well as reduced thermal expansion. Compared to conventional window assembly, the main advantage of sealed frame glazing unit is that through composite structural action, the required size of the sash profiles 197 can be significantly reduced resulting in improved energy efficiency and material cost reductions.
With composite structural action, the sealed frame panel performs in a similar manner to a stressed skin sandwich panel where the perimeter edges of the two glazing sheets 161 and 162 are respectively in compression and tension and so instead of the panel performing as two independent glazing sheets, the two sheets 161,162 act together as a structural unit.
The glazing sheets 161 and 162 are structurally adhered to the plastic frame profiles 197 with structural thermosetting sealant 195 and for long term durability, silicone sealant is the preferred material. For enhanced composite structural performance, a high modulus silicone sealant is required with the thickness of sealant being preferably less than 3 mm. To provide for increased panel stiffness, both the bottom edges 198 and perimeter side edges 199 of the glazing sheets 161 and 162 are adhered to L-shaped seats 200 on either side of the perimeter frame profiles 197. To allow glazing sheets 161 and 162 to bow in and out with changes in temperature and pressure, the side edge contact length is kept to a minimum with 10 mm being the typical length required.
A third center glazing sheet 196 is located between the two outer glazing sheets 161 and 162 and this glazing sheet is similar in shape but smaller in size than the outer two glazing sheets. For improved thermal performance, the width of the cavity spaces 201 and 202 between the glazing sheets 161,196 and 162 is typically between 9 and 18 mm. For improved energy efficiency, a low-e coating 203 can also be applied to one or more of the glass cavity surfaces of the window panel 193. In addition, the cavity spaces 161 and 162 can incorporate a low conductive gas such as argon or krypton.
To provide for long term gas retention as well as maintaining the integrity of the perimeter edge seal, there is a need for a continuous perimeter edge seal between the outer glazing sheets. Various edge seal configuration sand sealant materials can be used to provide this continuous barrier seal. One option as shown in
The rigid frame profiles 197 can be made from many alternative plastic materials produced using various processes. One preferred material is glass fiber-filled polyvinyl chloride (PVC) that is extruded to the required profile shape. One suitable product is Fiberloc 80530 that features a 30 percent glass fiber fill and is produced by Polyone Inc. of Cleveland Ohio. The co-efficient of thermal expansion of the 30 percent, glass fiber filled material is 18×10−6 cm/cm/° C. and this compares to the thermal coefficient of glass which is 9×10−6 cm/cm/° C. For very large panel sizes, the thermal expansion of the plastic profiles can be further reduced by reinforcing the frame profile walls 207 and 208 adjacent to the outer glass sheets 161 and 162 with continuous unidirectional glass fiber strips (not shown).
Instead of fiber glass reinforced PVC, the frame profiles 197 can be made from various other alternative plastic materials, including: thermoplastic fiber glass pultrusions, glass fiber reinforced engineering structural plastic foam extrusions and high draw oriented thermoplastic extrusions. Because the plastic profiles are firmly bonded to the glazing sheets and expand outwards from the mid points of the perimeter frame, maximum stress due to the differential expansion between the plastic profiles and the glass sheets occurs at the corners. Particularly with glass fiber filled profiles, because the corner welds are typically only as strong as the un-reinforced plastic, the corner welds can be a potential weak point in the frame assembly. To provide for increased strength and rigidity and to also reduce stress on the corner welds, the preferred assembly method is to join the plastic profiles together at the corners using a combination of friction corner welding and ultrasonic spot bonding and this production method has previously been described in
As previously shown in
As shown in
As shown in
As shown in
After the friction welding process is complete and as shown in