THERMAL INSULATING PROFILE

A thermal insulating profile includes: a first profile portion made of metal; a second profile portion made of metal; a thermal insulating material made of a foaming resin material, the thermal insulating material being configured to couple the first profile portion and the second profile portion to each other; an injection port formed, along a longitudinal direction of the thermal insulating profile, between the first profile portion and the second profile portion; and a closing member disposed at the injection port to close the injection port.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to and incorporates by reference the entire contents of Japanese Patent Application No. 2017-049811 filed in Japan on Mar. 15, 2017.

BACKGROUND 1. Technical Field

The disclosure relates to a thermal insulating profile that constitutes a construction member such as a frame member and a stile member for windows.

2. Related Art

In the related art, a thermal insulating profile manufactured as follows is known (see Japanese Laid-open Patent Publication No. 9-291756). First, in an aluminum extruded member formed by an outdoor member, an indoor member, and a coupling portion that couples the indoor and outdoor members to each other, a urethane resin is injected into a thermal insulating material injection pocket portion (cavity) having a concave groove shape surrounded by the indoor and outdoor members and the coupling portion. Next, after the urethane resin cures (is solidified) to be a thermal insulating material, the coupling portion between the outdoor member and the indoor member is cut and removed with a cutter or such other tools. The thermal insulating profile manufactured in this manner is used as a frame member for a sash window.

An injection port in the thermal insulating material injection pocket portion is opened along the longitudinal direction of the thermal insulating profile. An injection nozzle for the urethane resin is disposed above the injection port to inject the urethane resin into the injection pocket portion.

SUMMARY

After the urethane resin is injected into the injection pocket portion in the thermal insulating profile described in Japanese Laid-open Patent Publication No. 9-291756, the injection port remains unclosed, and hence the urethane resin, which is foamed when curing, may protrude from the injection port. This makes it difficult to employ a foaming resin material made of such a urethane resin.

The thermal insulating material obtained when the urethane resin cures is exposed in the injection port, and hence time and effort are necessary to finish the exposed surface part of the thermal insulating material. The material and the color of the exposed surface part are limited by the thermal insulating material, and hence it is difficult to increase the number of variations of the finished state.

It is desirable to provide a thermal insulating profile that can employ a thermal insulating material formed from a foaming resin material, that can eliminate burden of finishing a surface part exposed from an injection port, and that can increase the number of variations of the finished state of the surface part.

It is an object of the disclosure to at least partially solve the problems in the conventional technology.

According to one aspect of the disclosure, a thermal insulating profile includes: a first profile portion made of metal; a second profile portion made of metal; a thermal insulating material made of a foaming resin material, the thermal insulating material being configured to couple the first profile portion and the second profile portion to each other; an injection port formed, along a longitudinal direction of the thermal insulating profile, between the first profile portion and the second profile portion; and a closing member disposed at the injection port to close the injection port.

With the thermal insulating profile according to the disclosure, in the manufacturing of the thermal insulating profile, the foaming resin material in the liquid state can be injected into a region between the first profile portion and the second profile portion through the injection port, and then the injection port can be closed by the closing member. Thus, the foaming resin material, which is foamed when curing, can be prevented from protruding from the injection port, and hence a thermal insulating profile including a thermal insulating material obtained by foaming and curing the foaming resin material can be manufactured.

The outer surface of the closing member, rather than the thermal insulating material, is exposed from the injection port. Thus, by finishing the outer surface of the closing member in advance, time and effort for finishing treatment after the thermal insulating profile is manufactured can be eliminated. Furthermore, by selecting the material and the color of the closing member as appropriate, the number of variations of the outer surface of the closing member can be increased to improve the design of the thermal insulating profile.

The closing member can obtain the closing force by the foaming pressure of the foaming resin material, and hence the necessity of a mold closing device or jig can be eliminated. This leads to the omission of a mold opening step or a jig removal step after the curing step, and the productivity can be improved and the manufacturing cost can be reduced.

In the thermal insulating profile according to another aspect of the disclosure, the thermal insulating material may be formed of a foaming resin material having an expansion ratio of 3 to 5.

This configuration employs the foaming resin material to be injected through the injection port, which has an expansion ratio (expansion ratio in free state) of 3 to 5, and hence can reduce the amount of injection as compared with the case where a nonfoamable resin material is employed. A low-foaming resin material having an expansion ratio smaller than that of a general foaming resin material (such as a hard urethane foam having a free expansion ratio of 30 or more (density of 25 kg/m3)) cures, and hence a thermal insulating material having strength necessary as a construction member can be formed.

The above-mentioned foaming resin material in the disclosure can improve thermal insulating performance as compared with the case where a nonfoamable resin material is employed.

Specifically, the foaming resin material has a smaller amount of strain generated inside a molded product than a nonfoamable resin material, and hence after the foaming resin material is foamed and cures, the amount of resin shrinkage (dry shrinkage) is reduced. In the foaming resin material, the resin itself functions as a stress buffer, and hence an interface stress between the aluminum profile and the foaming resin material is reduced. Thus, the force acting in the direction in which the foaming resin material shrinks along the longitudinal direction of the thermal insulating profile after the foaming resin material is foamed and cures can be reduced to suppress the occurrence of deformation such as warpage and bending of the thermal insulating profile and cracks of the thermal insulating material.

In the thermal insulating profile according to still another aspect of the disclosure, the first profile portion and the second profile portion each may include a portion to be hooked, and the closing member may include a closing body portion disposed at the injection port and a hooking portion configured to be hooked to portions to be hooked of the first profile portion and the second profile portion.

This configuration enables the hooking portion of the closing member to be hooked to the portions to be hooked of the first profile portion and the second profile portion, and hence the closing body portion can be disposed at the injection port, and the injection port can be easily closed.

In the thermal insulating profile according to further another aspect of the disclosure, the hooking portion may include engaging protrusions that are elastically deformable, and the engaging protrusions may include distal end portions provided with claw portions to be engaged with the portions to be hooked of the first profile portion and the second profile portion.

This configuration enables the closing member to be pushed into the injection port from a direction orthogonal to the longitudinal direction of the first profile portion and the second profile portion, and hence the engaging protrusions can be pushed to the portions to be hooked of the first profile portion and the second profile portion and elastically deformed, so that the claw portions can be engaged with the respective portions to be hooked. The closing member can be easily mounted to the first profile portion and the second profile portion in a snap-fit manner.

In the thermal insulating profile according to further another aspect of the disclosure, the hooking portion may have a pair of the engaging protrusions, a protruding length dimension of the pair of the engaging protrusions between the closing body portion and the claw portions may be larger than a thickness dimension of the portions to be hooked of the first profile portion and the second profile portion, a dimension from a surface of one of the pair of the engaging protrusions that faces the portion to be hooked to a surface of another of the pair of the engaging protrusions that faces the portion to be hooked may be smaller than a width dimension of the injection port, and a dimension between distal ends of the claw portions along a width direction of the injection port may be larger than the width dimension of the injection port.

This configuration enables air escaping gaps to be formed between the closing member and the first profile portion and between the closing member and the second profile portion in a non-abutting state in which the claw portions of the pair of engaging protrusions are separated from the portions to be hooked of the first profile portion and the second profile portion. Thus, when the foaming resin material is foamed, the air can be efficiently escaped to the outside through the gaps.

In the thermal insulating profile according to further another aspect of the disclosure, the closing member may include a backing protrusion for the engaging protrusions, the backing protrusion protruding from the closing body portion.

This configuration enables the foaming resin material to enter between the engaging protrusions and the backing protrusion to cure when the foaming resin material is foamed, so that the foaming resin material serves as a backing member that receives the engaging protrusions. By forming the backing member in this manner, the closing member can be more firmly hooked to the first profile portion and the second profile portion.

In the thermal insulating profile according to further another aspect of the disclosure, an air escaping groove may be formed between the engaging protrusions and the closing body portion.

This configuration enables the air to be escaped into the above-mentioned air escaping grooves when the foaming resin material is foamed, and hence the foaming resin material can be efficiently foamed. Thus, the generation of air holes (air gaps) in the cavity can be prevented, and the foaming resin material can be evenly filled into the cavity between the first profile portion and the second profile portion.

In the thermal insulating profile according to further another aspect of the disclosure, a part of the engaging protrusions that abuts on the portions to be hooked of the first profile portion and the second profile portion may be formed from a soft resin material, and the closing member may be formed from a hard resin material except for the part formed from the soft resin material.

This configuration enables the parts of the engaging protrusions that are formed from the soft resin material to be brought into intimate contact with the portions to be hooked of the first profile portion and the second profile portion. Thus, the sealing degree by which the injection port is closed by the closing member can be improved.

In the thermal insulating profile according to further another aspect of the disclosure, a part of the closing member that abuts on a portion to be hooked of one of the first profile portion and the second profile portion may be formed from a soft resin material, and a part of the closing member that abuts on a portion to be hooked of another of the first profile portion and the second profile portion may be formed from a hard resin material.

This configuration enables, while the part of the closing member that is formed from the soft resin material is pushed against one portion to be hooked, the part of the closing member that is formed from the hard resin material to be pushed to the other portion to be hooked side, and hence the closing member can be easily positioned when the closing member is mounted. The closing member can be easily mounted with a small force.

The part of the closing member that is formed from the soft resin material reacts against the one portion to be hooked, and hence the part of the closing member that is formed from the hard resin material is pushed against the other portion to be hooked. Thus, the sealing degree by which the injection port is closed by the closing member can be improved.

In the thermal insulating profile according to further another aspect of the disclosure, open cells that are continuous from an inner surface on a thermal insulating material side to an outer surface on an exterior side may be formed in the closing member.

This configuration enables the air to be escaped to the outside through the open cells when the foaming resin material is foamed.

In the thermal insulating profile, a cavity may be formed between the first profile portion and the second profile portion, the closing member may include an abutment piece portion configured to abut on the first profile portion or the second profile portion in the cavity, and the abutment piece portion may be configured to partition the cavity into a thermal insulating space in which the thermal insulating material is disposed and a hollow space.

This configuration enables the cavity to be partitioned by the abutment piece portion of the closing member into the thermal insulating space and the hollow space. Thus, a screw hole or the like may be formed in the hollow space, and the thermal insulating material that couples the first profile portion and the second profile portion to each other can be disposed near the screw hole or the like.

The above and other objects, features, advantages and technical and industrial significance of this disclosure will be better understood by reading the following detailed description of presently preferred embodiments of the disclosure, when considered in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view illustrating a thermal insulating profile according to a first embodiment of the disclosure;

FIG. 2 is a sectional view illustrating a closing member for the thermal insulating profile according to the first embodiment;

FIG. 3 is a flowchart illustrating a procedure of manufacturing the thermal insulating profile according to the first embodiment;

FIG. 4A is a sectional view illustrating a preparation/pre-heating step for manufacturing the thermal insulating profile according to the first embodiment;

FIG. 4B is a sectional view illustrating a surface treatment step for manufacturing the thermal insulating profile according to the first embodiment;

FIG. 5A is a sectional view illustrating an injection step for manufacturing the thermal insulating profile according to the first embodiment;

FIG. 5B is a sectional view illustrating a closing step for manufacturing the thermal insulating profile according to the first embodiment;

FIG. 6A to FIG. 6C are sectional views illustrating principal portions of thermal insulating profiles according to second to fourth embodiments of the disclosure, respectively;

FIG. 7A to FIG. 7C are sectional views illustrating principal portions of a thermal insulating profile according to a fifth embodiment of the disclosure;

FIG. 8A and FIG. 8B are sectional views illustrating principal portions of thermal insulating profiles according to sixth and seventh embodiments of the disclosure;

FIG. 9A is a sectional view illustrating principal portions of a thermal insulating profile according to an eighth embodiment of the disclosure;

FIG. 9B and FIG. 9C are sectional views illustrating principal portions of a thermal insulating profile according to a ninth embodiment of the disclosure;

FIG. 10A and FIG. 10B are sectional views illustrating principal portions of a thermal insulating profile according to a tenth embodiment of the disclosure;

FIG. 11A and FIG. 11B are sectional views of principal portions of thermal insulating profiles according to eleventh and twelfth embodiments of the disclosure, respectively;

FIG. 12A and FIG. 12B are sectional views illustrating principal portions of thermal insulating profiles according to thirteenth and fourteenth embodiments of the disclosure;

FIG. 13A and FIG. 13B are sectional views illustrating principal portions of thermal insulating profiles according to fifteenth and sixteenth embodiments of the disclosure, respectively;

FIG. 14 is a sectional view illustrating a thermal insulating profile according to a seventeenth embodiment of the disclosure; and

FIG. 15 is a sectional view illustrating a thermal insulating profile according to an eighteenth embodiment of the disclosure.

 DETAILED DESCRIPTION First Embodiment

A first embodiment of the disclosure is described below with reference to the accompanying drawings.

In FIG. 1, a thermal insulating profile 1 according to the first embodiment is used as frame materials and stile materials for various kinds of sash windows. The thermal insulating profile 1 includes a first profile portion 20 on the outdoor side, a second profile portion 30 on the indoor side, and a thermal insulating material 50 made of a foaming resin material that couples the first profile portion 20 and the second profile portion 30 to each other.

The first profile portion 20 and the second profile portion 30 are formed by dividing (partitioning) an aluminum profile 10 formed of an extruded profile as a metal profile into an outdoor member and an indoor member, respectively.

A cavity 40A in which a thermal insulating material 50 is disposed is formed between the first profile portion 20 and the second profile portion 30.

A pair of extended piece portions 41A and 42A that are extended to the indoor side are formed at an indoor-side part of the first profile portion 20. A pair of extended piece portions 41B and 42B that are extended to the outdoor side are formed at an outdoor-side part of the second profile portion 30.

An injection port 43 along the longitudinal direction of the first profile portion 20 and the second profile portion 30 is formed between the extended piece portions 41A and 41B.

A gap 44 along the longitudinal direction of the first profile portion 20 and the second profile portion 30 is formed between the extended piece portions 42A and 42B.

Portions to be hooked 45A and 45B to which a closing member 60 described later is to be hooked are formed on the extended piece portions 41A and 41B, respectively.

A part of the first profile portion 20 where the cavity 40A is formed (extended piece portions 41A and 42A and part therebetween) and a part of the second profile portion 30 where the cavity 40A is formed (extended piece portions 41B and 42B and part therebetween) each have a thickness dimension of 1.0 mm, preferably 1.4 to 2.0 mm.

In the present embodiment, the cavity 40A has a sectional area of 40 mm2, preferably 60 to 2,000 mm2.

The thermal insulating material 50 in the present embodiment is formed by foaming and curing a foaming resin material 51 (see FIGS. 5A and 5B) whose expansion ratio in a free state is 3 to 5 in the cavity 40A. The foaming resin material 51 is made of a foamable urethane resin material in a liquid state. The thermal insulating material 50 has a tensile strength of 3 MPa or more as the resin strength necessary for coupling the first profile portion 20 and the second profile portion 30 to each other.

The thermal insulating profile 1 (thermal insulating aluminum profile) described above has a configuration in which the first profile portion 20 and the second profile portion 30 are partitioned from each other and are coupled to each other through the thermal insulating material 50. Thus, heat transfer between the first profile portion 20 and the second profile portion 30 is interrupted by the thermal insulating material 50.

In the injection port 43 formed between the first profile portion 20 and the second profile portion 30, a closing member 60 made of hard resin configured to close the injection port 43 is disposed.

As illustrated in FIG. 2, the closing member 60 includes a plate-shaped closing body portion 61 disposed at the injection port 43 and a hooking portion 62 that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The outer surface of the closing body portion 61 exposed from the injection port 43 is subjected to finishing treatment, and the outer surface is disposed to be flush with the outer surfaces of the extended piece portions 41A and 41B.

The hooking portion 62 is formed from a pair of engaging protrusions 63 and 64 that are elastically deformable.

At distal end portions of the engaging protrusions 63 and 64, claw portions 63A and 64A to be engaged with the portions to be hooked 45A and 45B are formed, respectively. The engaging protrusions 63 and 64 have equal protruding length dimensions. A dimension W1 between distal ends of the claw portions 63A and 64A along the width direction of the injection port 43 is larger than a width dimension W2 of the injection port 43 between the portions to be hooked 45A and 45B.

In the present embodiment, the distal end portions of the engaging protrusions 63 and 64 are round-chamfered to have an R of 0.8 or more, and the inclination angle of inclined surfaces of the engaging protrusions 63 and 64 with respect to the protruding direction thereof is set within the range of 45° to 60°. The round chamfering and the setting of the inclination angle can suppress the occurrence of removal of the closing member 60 and cracks in the hooking portion 62 due to the application of pressure to the inclined surfaces in the foaming and curing process of the foaming resin material 51.

Method of Manufacturing Thermal Insulating Profile

Referring to FIG. 3 to FIG. 5B, a method of manufacturing a thermal insulating profile according to the first embodiment is described below.

The thermal insulating profile 1 is manufactured through steps illustrated in FIG. 3, specifically, a preparation/pre-heating step S1 for preparing and pre-heating an aluminum profile 10, a surface treatment step S2 for treating the surface of a part of the aluminum profile 10 where a cavity 40A is to be formed, an injection step S3 for injecting a foaming resin material 51, a closing step S4 for closing the injection port 43, a curing step S5 for curing the foaming resin material 51, and a dividing step S6 for dividing the aluminum profile 10.

At the preparation/pre-heating step S1, the aluminum profile 10 is disposed at a predetermined position for preparation. In the aluminum profile 10, as illustrated in FIG. 4A, the injection port 43 is formed between the extended piece portions 41A and 41B, but the extended piece portions 42A and 42B are not divided and a continuous piece portion 42 is formed. Thus, the first profile portion 20 and the second profile portion 30 are continuous through a continuous piece portion 42. The prepared aluminum profile 10 is pre-heated to 40° C. or more.

At the surface treatment step S2, as illustrated in FIG. 4B, a surface of the aluminum profile 10 where the cavity 40A is to be formed is subjected to surface modification by discharge treatment such as corona discharge treatment and plasma discharge treatment by using a surface treatment device 55. The surface where the cavity 40A is to be formed is defined by inner surfaces of the extended piece portions 41A and 41B, an inner surface of the continuous piece portion 42, an indoor surface of a part of the first profile portion 20 between the extended piece portion 41A and the continuous piece portion 42, and an outdoor surface of a part of the second profile portion 30 between the extended piece portion 41B and the continuous piece portion 42.

At the injection step S3, as illustrated in FIG. 5A, the foaming resin material 51 in the liquid state is injected into the cavity 40A through the injection port 43 by using an injection device 52. In the present embodiment, the filling ratio of the foaming resin material 51 with respect to the cavity 40A falls within the range of 50% to 60%.

At the closing step S4, as illustrated in FIG. 5B, the closing member 60 is mounted to the aluminum profile 10 and disposed in the injection port 43. Specifically, the closing member 60 is mounted to the aluminum profile 10 as follows. By pushing the engaging protrusions 63 and 64 of the closing member 60 into the injection port 43, the engaging protrusions 63 and 64 are inserted into the cavity 40A while being elastically deformed. In this manner, the claw portion 63A of the engaging protrusion 63 is engaged with the portion to be hooked 45A of the extended piece portion 41A, and the claw portion 64A of the engaging protrusion 64 is engaged with the portion to be hooked 45B of the extended piece portion 41B. The closing member 60 is thus mounted to the aluminum profile 10 in a snap-fit manner.

At the curing step S5, the aluminum profile 10 is left for about 10 minutes while the closing member 60 is mounted. During the leaving time, the foaming resin material 51 cures while generating heat by itself. In this case, the foaming resin material 51 is foamed, and the cavity 40A is filled with the foaming resin material 51, and by using the foaming pressure of the foaming resin material 51, the sealing force is further improved. The injection port 43 is closed by the closing member 60, and hence the foaming resin material 51 is prevented from protruding from the injection port 43. As described above, after the foaming resin material 51 is foamed and cures, the foaming resin material 51 becomes the thermal insulating material 50.

At the dividing step S6, the continuous piece portion 42 is cut to form the extended piece portions 42A and 42B, and a gap 44 (see FIG. 1) is formed between the extended piece portions 42A and 42B. In this manner, the thermal insulating profile 1 in which the first profile portion 20 and the second profile portion 30 are partitioned from each other and are coupled to each other through the thermal insulating material 50 is formed.

In this manner, the thermal insulating profile 1 is manufactured.

Example

An example of the disclosure is described below.

In the method of manufacturing a thermal insulating profile described above, foaming resin materials 51 having expansion ratios in a free state of 3 to 8 were injected into the cavity 40A at filling ratios of 30% to 70% to execute the injection step S3 and manufacture thermal insulating profiles 1. The finished states and the resin strengths of thermal insulating materials 50 were compared. The finished state of the thermal insulating material 50 was evaluated as satisfactory when there was no insufficient filling of the thermal insulating material 50 in the cavity 40A, no protrusion of the thermal insulating material 50 from the injection port 43, or no deformation of the aluminum profile 10, and evaluated as poor when the such defects occurred. The resin strength of the thermal insulating material 50 was evaluated as satisfactory when the tensile strength was 3 MPa or more, and evaluated as poor when the tensile strength was less than 3 MPa. The results of the comparison are as illustrated in Table 1 indicating the relation between the free expansion ratio (free foam density) of the foaming resin material 51 and the filling ratio of the foaming resin material 51.

TABLE 1 Filling ratio ≤30% 40% 50% 60% 70%≤ Free 3 to 5 C B A A C expansion (400 to 220 ratio kg/m3) (free foam 6 to 8 C C C C C density) (220 to 140 kg/m3)

As illustrated in Table 1, when a foaming resin material 51 having a free expansion ratio of 3 to 5 (free foam density of 400 to 220 kg/m3) was injected into the cavity 40A at a filling ratio of 50% or 60% and cured, it was evaluated that the finished state of the thermal insulating material 50 was satisfactory and the resin strength was also satisfactory. This result was expressed as “A”.

When a foaming resin material 51 having a free expansion ratio of 3 to 5 (free foam density of 400 to 220 kg/m3) was injected into the cavity 40A at a filling ratio of 40% and cured, it was evaluated that the finished state of the thermal insulating material 50 was satisfactory while the resin strength was satisfactory in some parts and poor in other parts. This result was expressed as “B”.

When a foaming resin material 51 having a free expansion ratio of 3 to 5 (free foam density of 400 to 220 kg/m3) was injected into the cavity 40A at a filling ratio of 30% and cured, a finished state defect and a resin strength defect occurred due to insufficient filling of the thermal insulating material 50 in the cavity 40A. This result was evaluated as poor and was expressed as “C”.

When a foaming resin material 51 having a free expansion ratio of 3 to 5 (free foam density of 400 to 220 kg/m3) was injected into the cavity 40A at a filling ratio of 70% and cured and when a foaming resin material 51 having a free expansion ratio of 6 to 8 (free foam density of 220 to 140 kg/m3) was injected into the cavity 40A at a filling ratio of 30%, 40%, 50%, 60%, or 70% and cured, finished state defects such as the protrusion of the thermal insulating material 50 from the injection port 43 and the deformation of the aluminum profile 10 and a resin strength defect occurred. This result was evaluated as poor and was expressed as “C”.

Effects in First Embodiment

(1) In the first embodiment, the thermal insulating profile 1 includes: the first profile portion 20 made of metal; the second profile portion 30 made of metal; the thermal insulating material 50 made of a foaming resin material, the thermal insulating material being configured to couple the first profile portion 20 and the second profile portion 30 to each other; the injection port 43, along the longitudinal direction of the thermal insulating profile 1, between the first profile portion 20 and the second profile portion 30, the thermal insulating material 50 is made of a foaming resin material; and the closing member 60 disposed at the injection port to close the injection port 43.

With the above-mentioned configuration, in the manufacturing of the thermal insulating profile 1, the foaming resin material 51 in the liquid state can be injected into a region between the first profile portion 20 and the second profile portion 30 through the injection port 43, and then the injection port 43 can be closed by the closing member 60. Thus, the foaming resin material 51, which is foamed when curing, can be prevented from protruding from the injection port 43, and hence the thermal insulating profile 1 including the thermal insulating material 50 obtained by foaming and curing the foaming resin material 51 can be manufactured.

The outer surface of the closing member 60, rather than the thermal insulating material 50, is exposed from the injection port 43. Thus, by finishing the outer surface of the closing member 60 in advance, time and effort for finishing treatment after the thermal insulating profile 1 is manufactured can be eliminated. Furthermore, by selecting the material and the color of the closing member 60 as appropriate, the number of variations of the outer surface of the closing member 60 can be increased to improve the design of the thermal insulating profile 1.

The closing member 60 can obtain the closing force by the foaming pressure of the foaming resin material 51, and hence the necessity of a mold closing device or jig can be eliminated. This leads to the omission of a mold opening step or a jig removal step after the curing step, and the productivity can be improved and the manufacturing cost can be reduced.

Furthermore, the present embodiment can exhibit the following effects.

(2) In the first embodiment, the thermal insulating material 50 is formed of the foaming resin material 51 having an expansion ratio of 3 to 5.

Thus, by employing the foaming resin material 51 having an expansion ratio (expansion ratio in free state) of 3 to 5 as the foaming resin material injected through the injection port 43, the amount of injection can be reduced as compared with the case where a nonfoamable resin material is employed. A low-foaming resin material 51 having an expansion ratio smaller than that of a general foaming resin material cures, and hence a thermal insulating material 50 having strength necessary as a construction member can be formed.

The foaming resin material 51 employed in the first embodiment can improve thermal insulating performance as compared with the case where a nonfoamable resin material is employed.

(3) In the first embodiment, the first profile portion 20 and the second profile portion 30 include the portions to be hooked 45A and 45B formed thereon, and the closing member 60 includes the closing body portion 61 disposed at the injection port 43 and the hooking portion 62 configured to be hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

Thus, the closing body portion 61 can be disposed at the injection port 43 in a manner that the hooking portion 62 of the closing member 60 is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30. Consequently, the injection port 43 can be easily closed.

(4) In the first embodiment, the hooking portion 62 includes the engaging protrusions 63 and 64 that are elastically deformable, and the engaging protrusions 63 and 64 include distal end portions provided with the claw portions 63A and 64A to be engaged with the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30, respectively.

Thus, when the closing member 60 is pushed into the injection port 43 from the direction orthogonal to the longitudinal direction of the first profile portion 20 and the second profile portion 30, the engaging protrusions 63 and 64 are pushed against the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30 to be elastically deformed. Consequently, the claw portions 63A and 64A can be engaged with the portions to be hooked 45A and 45B, respectively, and the closing member 60 can be easily mounted to the first profile portion 20 and the second profile portion 30 in a snap-fit manner.

Second Embodiment

Referring to FIG. 6A, a thermal insulating profile 2A according to a second embodiment of the disclosure is described below.

The thermal insulating profile 2A is configured substantially similarly to the thermal insulating profile 1 in the first embodiment, but includes a closing member 70A instead of the closing member 60.

The closing member 70A includes a closing body portion 71A disposed at the injection port 43, and a hooking portion 72A that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The closing body portion 71A is configured similarly to the closing body portion 61 in the first embodiment.

The hooking portion 72A bulges to the thermal insulating material 50 side from the closing body portion 71A, and claw portions 721A and 722A engaged with the portions to be hooked 45A and 45B are formed. A surface of the hooking portion 72A on the side of the extended piece portions 42A and 42B is formed into an arc shape that is convex toward the extended piece portions 42A and 42B in a sectional view of the thermal insulating profile 2A illustrated in FIG. 6A.

The closing member 70A is inserted into the injection port 43 from an end portion of the above-mentioned aluminum profile 10 in the longitudinal direction and is disposed in the injection port 43.

With this configuration, when the foaming resin material 51 injected into the cavity 40A is foamed in the manufacturing of the thermal insulating profile 2A, a foaming pressure applied to the closing member 70A from the foaming resin material 51 can be dispersed. Thus, the possibility of the occurrence of resin cracks in the closing member 70A due to the foaming pressure can be reduced.

Third Embodiment

Referring to FIG. 6B, a thermal insulating profile 2B according to a third embodiment of the disclosure is described below.

The thermal insulating profile 2B is formed substantially similarly to the thermal insulating profile 1 in the first embodiment, but includes a closing member 70B instead of the closing member 60.

The closing member 70B includes a closing body portion 71B disposed at the injection port 43, and a hooking portion 72B that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The closing body portion 71B is configured similarly to the closing body portion 61 in the first embodiment.

The hooking portion 72B is formed from a pair of engaging protrusions 73B and 74B that are elastically deformable. At distal end portions of the engaging protrusions 73B and 74B, claw portions 731B and 741B to be engaged with the portions to be hooked 45A and 45B are formed, respectively.

Each of distal end portions of the engaging protrusions 73B and 74B is an expanded portion, and a surface of the expanded portion on the side of the extended piece portions 42A and 42B is formed into an arc shape that is convex toward the extended piece portions 42A and 42B in a sectional view of the thermal insulating profile 2B illustrated in FIG. 6B.

When the closing member 70B is pushed into the injection port 43, the claw portions 731B and 741B are engaged with the portions to be hooked 45A and 45B in a snap-fit manner, and the closing member 70B is disposed in the injection port 43.

With this configuration, when the foaming resin material 51 injected into the cavity 40A is foamed in the manufacturing of the thermal insulating profile 2B, a foaming pressure applied to the engaging protrusions 73B and 74B of the closing member 70B from the foaming resin material 51 can be dispersed. Thus, the possibility of the occurrence of resin cracks in the closing member 70B due to the foaming pressure can be reduced.

Fourth Embodiment

Referring to FIG. 6C, a thermal insulating profile 2C according to a fourth embodiment of the disclosure is described below.

The thermal insulating profile 2C is formed substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a closing member 70C instead of the closing member 60.

The closing member 70C includes a closing body portion 71C disposed at the injection port 43, and a hooking portion 72C that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The closing body portion 71C is configured similarly to the closing body portion 61 in the first embodiment.

The hooking portion 72C is formed from a pair of engaging protrusions 73C and 74C. At distal end portions of the engaging protrusions 73C and 74C, claw portions 731C and 741C to be engaged with the portions to be hooked 45A and 45B are formed, respectively.

A surface of the closing member 70C between the engaging protrusions 73C and 74C is formed into an arc shape that is concave toward the extended piece portions 42A and 42B.

When the closing member 70C is pushed into the injection port 43, the claw portions 731C and 741C are engaged with the portions to be hooked 45A and 45B in a snap-fit manner, and the closing member 70C is disposed in the injection port 43.

With this configuration, when the foaming resin material 51 injected into the cavity 40A in the manufacturing of the thermal insulating profile 2C is foamed, a foaming pressure applied to the closing member 70C from the foaming resin material 51 can be dispersed. Thus, the possibility of the occurrence of resin cracks in the closing member 70C due to the foaming pressure can be reduced.

Fifth Embodiment

Referring to FIG. 7A to FIG. 7C, a thermal insulating profile 3 according to a fifth embodiment of the disclosure is described below.

As illustrated in FIG. 7A, the thermal insulating profile 3 is formed substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a closing member 80 instead of the closing member 60.

The closing member 80 includes a plate-shaped closing body portion 81 disposed at the injection port 43, and a hooking portion 82 that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30. The closing member 80 is configured substantially similarly to the closing member 60 in the first embodiment, but has dimensions that are set differently from the closing member 60.

The hooking portion 82 is formed from a pair of engaging protrusions 83 and 84 that are elastically deformable. At distal end portions of the engaging protrusions 83 and 84, claw portions 83A and 84A to be engaged with the portions to be hooked 45A and 45B are formed, respectively.

As illustrated in FIG. 7B, a protruding length dimension L1 of the engaging protrusion 83 between the closing body portion 81 and the claw portion 83A is larger than the thickness dimension of the portion to be hooked 45A. A protruding length dimension L2 of the engaging protrusion 84 between the closing body portion 81 and the claw portion 84A is larger than the thickness dimension of the portion to be hooked 45B. The protruding length dimensions L1 and L2 of the engaging protrusions 83 and 84 are equal to each other.

A dimension W1 between distal ends of the claw portions 83A and 84A along the width direction of the injection port 43 is larger than a width dimension W2 of the injection port 43 between the portions to be hooked 45A and 45B.

A dimension W3 from a surface of the engaging protrusion 83 that faces the portion to be hooked 45A to a surface of the engaging protrusion 84 that faces the portion to be hooked 45B is smaller than the width dimension W2 of the injection port 43 between the portions to be hooked 45A and 45B.

A width dimension W4 of the closing body portion 81 is smaller than a width dimension W5 between the side edges of the extended piece portions 41A and 41B excluding the portions to be hooked 45A and 45B.

When the closing member 80 is pushed into the injection port 43, the claw portions 83A and 84A are engaged with the portions to be hooked 45A and 45B in a snap-fit manner, and the closing member 80 is disposed in the injection port 43 as illustrated in FIG. 7B.

When the foaming resin material 51 injected into the cavity 40A is foamed, as illustrated in FIG. 7C, the air in the cavity 40A is released to the outside through the gap between the closing member 80 and the extended piece portion 41A and the gap between the closing member 80 and the extended piece portion 41B. The closing member 80 is pushed out to the outside by the foaming resin material 51, and when the claw portions 83A and 84A of the closing member 80 abut on the portions to be hooked 45A and 45B, the gap between the closing member 80 and the extended piece portion 41A and the gap between the closing member 80 and the extended piece portion 41B are closed, and the cavity 40A is sealed.

As described above, the air escaping gaps can be formed between the closing member 80 and the first profile portion 20 and between the closing member 80 and the second profile portion 30 in the non-abutting state in which the claw portions 83A and 84A of the engaging protrusions 83 and 84 are separated from the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30. Thus, when the foaming resin material 51 is foamed, the air can be efficiently escaped to the outside through the gaps, and the generation of air holes (air gaps) in the cavity 40A can be prevented, so that the foaming resin material 51 can be evenly filled into the cavity 40A.

Sixth Embodiment

Referring to FIG. 8A, a thermal insulating profile 4A according to a sixth embodiment of the disclosure is described below.

The thermal insulating profile 4A is formed substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a closing member 90A instead of the closing member 60.

The closing member 90A includes a plate-shaped closing body portion 91A disposed at the injection port 43, and a hooking portion 92A that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The hooking portion 92A is formed from a pair of engaging protrusions 93A and 94A that are elastically deformable. At distal end portions of the engaging protrusions 93A and 94A, claw portions 931A and 941A to be engaged with the portions to be hooked 45A and 45B are formed, respectively.

In the closing member 90A, a backing protrusion 95A that protrudes from the closing body portion 91A between the engaging protrusions 93A and 94A is formed. The backing protrusion 95A is disposed with gaps from the engaging protrusions 93A and 94A. The backing protrusion 95A is formed to be thinner on the base end side than on the distal end side, and hence air escaping grooves 96A are formed between a distal end portion of the backing protrusion 95A and the closing body portion 91A. A part of the closing body portion 91A between the engaging protrusions 93A and 94A is formed to be thinner than a part of the closing body portion 91A other than the part between the engaging protrusions 93A and 94A, and hence an air escaping space is expanded between the engaging protrusions 93A and 94A.

With this configuration, when the foaming resin material 51 is foamed and enters between the engaging protrusions 93A and 94A and the backing protrusion 95A to cure, the foaming resin material 51 serves as a backing member that receives the engaging protrusions 93A and 94A. By forming the backing member in this manner, the closing member 90A can be more firmly hooked to the first profile portion 20 and the second profile portion 30.

When the foaming resin material 51 is foamed, the air can be escaped into the above-mentioned air escaping grooves 96A, and hence the foaming resin material 51 can be efficiently foamed. Thus, the foaming resin material 51 can be evenly filled into the cavity 40A.

Seventh Embodiment

Referring to FIG. 8B, a thermal insulating profile 4B according to a seventh embodiment of the disclosure is described below.

The thermal insulating profile 4B is formed substantially similarly to the thermal insulating profile 4A according to the sixth embodiment, but includes a closing member 90B in which the air escaping grooves 96A for the closing member 90A are different.

In FIG. 8B, the same components in the closing member 90B as those in the closing member 90A are denoted by the same reference symbols as those in the closing member 90A.

Air escaping grooves 96B for the closing member 90B are formed to be thinner on the base end side of the backing protrusion 95A than on the distal end side thereof, and the grooves are expanded from the base end side of the backing protrusion 95A toward the distal end thereof. Thus, the closing member 90B can cause a larger amount of air to be escaped to the air escaping grooves 96B than the closing member 90A in the sixth embodiment.

Eighth Embodiment

Referring to FIG. 9A, a thermal insulating profile 5A according to an eighth embodiment of the disclosure is described below.

The thermal insulating profile 5A is formed substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a closing member 100 instead of the closing member 60.

The closing member 100 includes a closing body portion 101 disposed at the injection port 43, and a hooking portion 102 that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The closing body portion 101 is configured similarly to the closing body portion 61 in the first embodiment.

The hooking portion 102 is formed from a pair of engaging protrusions 103 and 104 that are elastically deformable. At distal end portions of the engaging protrusions 103 and 104, claw portions 103A and 104A to be engaged with the portions to be hooked 45A and 45B are formed, respectively.

A part of the engaging protrusion 103 that abuts on the portion to be hooked 45A of the first profile portion 20 is formed from a soft resin material. A part of the engaging protrusion 104 that abuts on the portion to be hooked 45B of the second profile portion 30 is formed from a soft resin material.

The closing member 100 is formed from a hard resin material except for the above-mentioned part formed from the soft resin material. The closing member 100 is molded to have two layers made of the soft resin material and the hard resin material.

This configuration enables the parts of the engaging protrusion 103 and 104 formed from the soft resin material to be brought into intimate contact with the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30. By using the reacting property of the soft resin material, the sealing degree of the injection port 43 by the closing member 100 can be improved.

Ninth Embodiment

Referring to FIG. 9B, a thermal insulating profile 5B according to a ninth embodiment of the disclosure is described below.

The thermal insulating profile 5B is formed substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a closing member 110 instead of the closing member 60.

As illustrated in FIG. 9B, the closing member 110 includes a plate-shaped closing body portion 111 disposed at the injection port 43, and a hooking portion 112 that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

The hooking portion 112 is formed from a pair of engaging protrusions 113 and 114 that are elastically deformable. At distal end portions of the engaging protrusions 113 and 114, claw portions 113A and 114A to be engaged with the portions to be hooked 45A and 45B are formed, respectively.

A part of the closing member 110 that abuts on the extended piece portion 41A of the first profile portion 20 is formed from a soft resin material, and the closing member 110 is formed from a hard resin material except for the part. The part formed from the soft resin material is a part of the closing body portion 111 that is located on the extended piece portion 41A side and a part of the engaging protrusion 113 that is located on the portion to be hooked 45A side. A surface of the part formed from the soft resin material that is continuous from the closing body portion 111 to the engaging protrusion 113 is formed as an inclined surface 115 that is inclined with respect to the width direction of the closing member 110. The closing member 110 is molded to have two layers made of the soft resin material and the hard resin material.

As illustrated in FIG. 9C, first, the engaging protrusion 113 of the closing member 110 is inserted into the injection port 43 and is hooked to the portion to be hooked 45A. Because the above-mentioned inclined surface 115 is formed, the closing member 110 can be easily disposed to be inclined with respect to the injection port 43. When the claw portion 113A is formed to have a large protruding dimension along the width direction of the closing member 110, the engaging protrusion 113 can be hooked deep to the portion to be hooked 45A even in the state in which the closing member 110 is inclined with respect to the injection port 43, and hence the ease of positioning of the closing member 110 in this state can be improved. Next, the engaging protrusion 114 is pushed into the injection port 43 and is hooked to the portion to be hooked 45B. In this manner, the closing member 110 is disposed in the injection port 43.

As described above, a part of the closing member 110 that abuts on the portion to be hooked 45A is formed from a soft resin material, and a part of the closing member 110 that abuts on the portion to be hooked 45B is formed from a hard resin material. Thus, while the part of the closing member 110 that is formed from the soft resin material is pushed against the portion to be hooked 45A, the part of the closing member 110 that is formed from the hard resin material can be pushed to the portion to be hooked 45B, and hence the closing member 110 can be easily positioned when the closing member 110 is mounted. The closing member 110 can be easily mounted with a small force.

The part of the closing member 110 that is formed from the soft resin material reacts against the portion to be hooked 45A, and hence the part of the closing member 110 that is formed from the hard resin material is pushed against the portion to be hooked 45B. Thus, the sealing degree by which the injection port 43 is closed by the closing member 110 can be improved.

Tenth Embodiment

Referring to FIGS. 10A and 10B, a thermal insulating profile 6 according to a tenth embodiment of the disclosure is described below.

As illustrated in FIG. 10A, the thermal insulating profile 6 is formed substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a closing member 118 instead of the closing member 60.

The closing member 118 is configured similarly to the closing member 60 according to the first embodiment, but is formed from a resin having an open-cell structure, and cells (open cells) are continuous from the inner surface on the cavity 40A side to the outer surface on the exterior side.

Thus, when the foaming resin material 51 injected into the cavity 40A is foamed, air in the cavity 40A is released to the outside through the open cells as illustrated in FIG. 10B. The foaming resin material 51 enters the open cells halfway as illustrated in FIG. 10A, and the cavity 40A is sealed. In this manner, the air in the cavity 40A can be escaped to the outside through the open cells.

Eleventh Embodiment

Referring to FIG. 11A, a thermal insulating profile 11A according to an eleventh embodiment of the disclosure is described below.

The thermal insulating profile 11A is configured substantially similarly to the thermal insulating profile 1 according to the first embodiment, but includes a sliding type closing member 140A instead of the snap-fit type closing member 60.

The closing member 140A includes a closing body portion 141 disposed at the injection port 43, and a hooking portion that is hooked to the portions to be hooked 45A and 45B of the first profile portion 20 and the second profile portion 30.

A hollow portion is formed in the closing body portion 141. The outer surface of the closing body portion 141 exposed from the injection port 43 is subjected to finishing treatment, and the outer surface is disposed to be flush with the outer surfaces of the extended piece portions 41A and 41B.

The hooking portion is formed from insertion piece portions 143 and 144 that extend in the lateral direction in FIG. 11A. The insertion piece portions 143 and 144 are disposed with a gap in the vertical direction from a corresponding one of both lateral edge portions of the closing body portion 141. The portions to be hooked 45A and 45B are disposed in the gaps.

The closing member 140A is slidingly inserted to the injection port 43 from one end portion of the aluminum profile 10 in the longitudinal direction. Then, the insertion piece portions 143 and 144 are disposed in the cavity 40A, the closing body portion 141 is disposed in the injection port 43, and the portions to be hooked 45A and 45B are disposed in the gaps between the insertion piece portions 143 and 144 and both edge portions of the closing body portion 141.

The sliding type closing member 140A as described above can also close the injection port 43.

Twelfth Embodiment

Referring to FIG. 11B, a thermal insulating profile 11B according to a twelfth embodiment of the disclosure is described below.

The thermal insulating profile 11B is configured substantially similarly to the thermal insulating profile 11A according to the eleventh embodiment, but includes a closing member 140B instead of the closing member 140A. The closing member 140B is configured substantially similarly to the closing member 140A, but the closing member 140B is formed such that the vertical thickness of both lateral edge portions of the closing body portion 141 are smaller than that of both edge portions of the closing member 140A. The closing member 140B is formed such that vertical gaps between both lateral edge portions of the closing member 140B and the insertion piece portions 143 and 144 are larger than the vertical gaps between both lateral edge portions of the closing member 140A and the insertion piece portions 143 and 144.

Thus, when the foaming resin material 51 in the cavity 40A is foamed, the thermal insulating profile 11B is located at a lowered position, and hence air can be escaped to the outside through gaps between the first profile portion 20 and the portion to be hooked 45A and between the second profile portion 30 and the portion to be hooked 45B.

After the foaming resin material 51 is foamed and cures, the insertion piece portion 143,144 and the portions to be hooked 45A and 45B come into intimate contact with each other, and hence the injection port 43 can be closed.

Thirteenth Embodiment

Referring to FIG. 12A, a thermal insulating profile 12A according to a thirteenth embodiment of the disclosure is described below.

The thermal insulating profile 12A includes a first profile portion 20, a second profile portion 30, and a closing member 150A. The first profile portion 20 and the second profile portion 30 include, as portions to be hooked, concave groove forming portions 48A and 48B formed at edges of the extended piece portions 41A and 41B instead of the portions to be hooked 45A and 45B in the above-mentioned first embodiment.

The closing member 150A includes a closing body portion 151 disposed at the injection port 43, and a hooking portion 152 that is hooked to the concave groove forming portion 48A of the first profile portion 20 and the concave groove forming portion 48B of the second profile portion 30. In FIG. 12A, the hooking portion 152 includes engaging protrusions 153 and 154 that protrude from the closing body portion 151 in the lateral direction.

Also in the thermal insulating profile 12A, the injection port 43 can be closed by engaging the engaging protrusions 153 and 154 of the closing member 150A with the concave groove forming portions 48A and 48B of the first profile portion 20 and the second profile portion 30.

Fourteenth Embodiment

Referring to FIG. 12B, a thermal insulating profile 12B according to a fourteenth embodiment of the disclosure is described below.

Substantially similarly to the thirteenth embodiment, the thermal insulating profile 12B includes a first profile portion 20 and a second profile portion 30 having concave groove forming portions 49A and 49B as portions to be hooked, respectively, and a closing member 150B.

Substantially similarly to the closing member 150A, the closing member 150B includes a closing body portion 161 and a hooking portion 162 that is hooked to the concave groove forming portion 49A of the first profile portion 20 and the concave groove forming portion 49B of the second profile portion 30. In FIG. 12B, the hooking portion 162 includes engaging protrusions 163 and 164 that protrude from the closing body portion 161 in the lateral direction.

Vertical thickness dimensions of the engaging protrusions 163 and 164 are set to be smaller than vertical dimensions of concave grooves formed by the concave groove forming portions 49A and 49B, and gaps are formed between the engaging protrusions 163 and 164 and the concave groove forming portions 49A and 49B in the vertical direction.

Thus, when the foaming resin material 51 in the cavity 40A is foamed, the thermal insulating profile 12B is located at a lowered position, and hence air can be escaped to the outside through the gaps between the engaging protrusions 163 and 164 of the thermal insulating profile 12B and the concave groove forming portions 49A and 49B.

After the foaming resin material 51 is foamed and cures, the engaging protrusions 163 and 164 and the concave groove forming portions 49A and 49B come into intimate contact with each other, and hence the injection port 43 can be closed.

Fifteenth Embodiment

Referring to FIG. 13A, a thermal insulating profile 13A according to a fifteenth embodiment of the disclosure is described below.

Substantially similarly to the first embodiment, the thermal insulating profile 13A includes a first profile portion 20 and a second profile portion 30 having portions to be hooked 45A and 45B, respectively, but has a closing member 170A instead of the closing member 60.

The closing member 170A includes a closing body portion 171 disposed at the injection port 43, and engaging protrusions 63 and 64 (the same engaging protrusions as in the first embodiment) as hooking portions that protrude from the closing body portion 171.

A hollow portion 172 is formed in the closing body portion 171. The hollow portion 172 communicates to the cavity 40A through a hole 173 formed in the closing body portion 171 on the cavity 40A side.

By forming the hole 173 in the closing body portion 171, the foaming resin material 51 to be foamed can be escaped to the hollow portion 172 to prevent the generation of air holes, and the foaming resin material 51 can be evenly filled into the cavity 40A. By forming the hole 173 connected to the hollow portion 172, the foaming pressure of the foaming resin material 51 can be reduced. For example, the filling ratio of the foaming resin material 51 with respect to the cavity 40A can be set to be 70% or more. The resin density of the molded thermal insulating material 50 can be increased to improve the strength. In addition, the pressure applied to the closing member 170A when the foaming resin material 51 is foamed is decreased, and hence the closing member 170A can be thinned to reduce the cost for the closing member 170A itself.

Sixteenth Embodiment

Referring to FIG. 13B, a thermal insulating profile 13B according to a sixteenth embodiment of the disclosure is described below.

The thermal insulating profile 13B has substantially the same as the thermal insulating profile 13A according to the fifteenth embodiment, but includes a closing member 170B instead of the closing member 170A.

The closing member 170B is formed substantially similarly to the thermal insulating profile 11B according to the twelfth embodiment, but a hole 173 for communicating a hollow portion 142 of the closing body portion 141 to the cavity 40A is formed.

As described above, when the foaming resin material 51 in the cavity 40A is foamed, the thermal insulating profile 13B enables air to be released through gaps between the first profile portion 20 and the closing member 170B and the second profile portion 30 and the closing member 170B similarly to the thermal insulating profile 11B according to the twelfth embodiment. Similarly to the thermal insulating profile 13A according to the fifteenth embodiment, the foaming resin material 51 can be escaped into the hollow portion 142 through the hole 173. Thus, the above-mentioned functions and effects in the twelfth and fifteenth embodiments can be exhibited.

Seventeenth Embodiment

Referring to FIG. 14, a thermal insulating profile 7 according to a seventeenth embodiment of the disclosure is described below.

In FIG. 14, the thermal insulating profile 7 includes a first profile portion 20A on the outdoor side, a second profile portion 30A on the indoor side, and a thermal insulating material 50 made of a foaming resin material that couples the first profile portion 20A and the second profile portion 30A to each other.

The first profile portion 20A and the second profile portion 30A are formed by dividing (partitioning) an aluminum profile 10A into an outdoor member and an indoor member, respectively. A cavity 40A is formed between the first profile portion 20A and the second profile portion 30A.

The first profile portion 20A includes a side piece portion 21A and a drooping piece portion 22A that droops from the side piece portion 21A. A screw hole portion 23A is formed at a part where the side piece portion 21A and the drooping piece portion 22A are continuous. A distal end portion of the drooping piece portion 22A forms a portion to be hooked 25A that is extended to the indoor side.

The second profile portion 30A includes a side piece portion 31A and a raising piece portion 32A that is raised from the side piece portion 31A. An end portion of the side piece portion 31A on the outdoor side forms a portion to be hooked 35A.

The injection port 43 is formed between the portions to be hooked 25A and 35A. When the aluminum profile 10A is divided into the first profile portion 20A and the second profile portion 30A, the raising piece portion 32A is cut away from the first profile portion 20A, and a gap 44 is formed between the raising piece portion 32A and an end portion of the side piece portion 21A on the indoor side.

In the injection port 43 illustrated in FIG. 14, a closing member 120 is disposed. The closing member 120 includes a closing body portion 121 disposed at the injection port 43, and a hooking portion 122 that is hooked to the portions to be hooked 25A and 35A of the first profile portion 20A and the second profile portion 30A.

The closing body portion 121 is configured similarly to the closing body portion 61 in the first embodiment.

The hooking portion 122 is formed from a pair of engaging protrusions 123 and 124 that are elastically deformable. The engaging protrusions 123 and 124 are formed similarly to the engaging protrusions 63 and 64 in the first embodiment.

On the closing member 120, an abutment piece portion 125 that protrudes from the closing body portion 121 between the engaging protrusions 123 and 124 is formed. The abutment piece portion 125 has a protruding length dimension larger than protruding length dimensions of the engaging protrusions 123 and 124. As illustrated in FIG. 14, the abutment piece portion 125 abuts on the screw hole portion 23A of the first profile portion 20A in the state in which the closing member 120 is disposed in the injection port 43. The cavity 40A is partitioned into a thermal insulating space 46A and a hollow space 47A by the above-mentioned abutment piece portion 125.

In this manner, the cavity 40A is partitioned into the thermal insulating space 46A and the hollow space 47A by the abutment piece portion 125 of the closing member 120, and hence the screw hole portion 23A may be formed in the hollow space 47A. When the screw hole portion 23A is formed, the thermal insulating material 50 that couples the first profile portion 20A and the second profile portion 30A to each other can be disposed near the screw hole portion 23A.

Eighteenth Embodiment

Referring to FIG. 15, a thermal insulating profile 8 according to an eighteenth embodiment of the disclosure is described below.

The thermal insulating profile 8 is formed substantially similarly to the thermal insulating profile 7 according to the seventeenth embodiment, but the hooking shape of a closing member 130 to a first profile portion 20B and a second profile portion 30B is different.

The thermal insulating profile 8 includes a first profile portion 20B on the outdoor side, a second profile portion 30B on the indoor side, and a thermal insulating material 50 made of a foaming resin material that couples the first profile portion 20B and the second profile portion 30B to each other.

The first profile portion 20B and the second profile portion 30B are formed by dividing (partitioning) an aluminum profile 10B into an outdoor member and an indoor member, respectively. A cavity 40A is formed between the first profile portion 20B and the second profile portion 30B.

The first profile portion 20B includes a side piece portion 21B and a drooping piece portion 22B that droops from the side piece portion 21B. A screw hole portion 23B is formed at a part the side piece portion 21B and the drooping piece portion 22B are continuous. A portion to be hooked 25B is formed on a surface of the drooping piece portion 22B on the screw hole portion 23B side. A portion to be hooked 26B is formed on the screw hole portion 23B as well.

The second profile portion 30B includes a side piece portion 31B and a raising piece portion 32B that is raised from the side piece portion 31B. An end portion of the side piece portion 31B on the outdoor side forms a portion to be hooked 35B.

The injection port 43 is formed between a distal end portion of the drooping piece portion 22B and the portion to be hooked 35B. When the aluminum profile 10B is divided into the first profile portion 20B and the second profile portion 30B, the raising piece portion 32B is cut away from the first profile portion 20B, and a gap 44 is formed between an end portion of the side piece portion 21B on the indoor side.

In the injection port 43 illustrated in FIG. 15, a closing member 130 is disposed. The closing member 130 includes a plate-shaped closing body portion 131 disposed at the injection port 43, and a hooking portion 132 that is hooked to the portions to be hooked 25B and 35B of the first profile portion 20B and the second profile portion 30B.

The hooking portion 132 includes an engaging protrusion 133 that protrudes from an end portion of the closing body portion 131 on the first profile portion 20B side, an engaging portion 134 that is formed at an end portion of the closing body portion 131 on the second profile portion 30B side, and an abutment piece portion 135 that protrudes from the closing body portion 131 between the engaging protrusion 133 and the engaging portion 134. An engaging portion 136 is formed at a distal end portion of the abutment piece portion 135.

The engaging protrusion 133 is engaged with the portion to be hooked 25B, the engaging portion 134 is engaged with the portion to be hooked 35B, and the engaging portion 136 of the abutment piece portion 135 is engaged with the portion to be hooked 26B of the screw hole portion 23B. The cavity 40A is partitioned into a thermal insulating space 46B and a hollow space 47B by the above-mentioned abutment piece portion 135.

In this manner, the abutment piece portion 135 of the closing member 130 partitions the cavity 40A into the thermal insulating space 46B and the hollow space 47B, and hence the screw hole portion 23B may be formed in the hollow space 47B. When the screw hole portion 23B is formed, the thermal insulating material 50 that couples the first profile portion 20B and the second profile portion 30B to each other can be disposed near the screw hole portion 23B.

Modifications

The disclosure is not limited to the configurations described above in the above-mentioned embodiments, and such modifications that can achieve the object of the disclosure are included in the disclosure.

For example, in the above-mentioned embodiments, the metal profile is the aluminum profile 10, 10A, or 10B formed from an aluminum extruded profile. Without being limited thereto, the metal profile may be made of iron, steel, stainless steel, or magnesium.

In the above-mentioned embodiments, the foaming resin material 51 whose expansion ratio in the free state is 3 to 5 is injected into the cavity 40A at a filling ratio of 50% to 60%. Without being limited thereto, the expansion ratio and the filling ratio may be freely selected as long as a finished state defect and a resin strength defect do not occur in the thermal insulating material 50. For example, a foaming resin material 51 whose expansion ratio in the free state is less than 3 or more than 5 may be injected into the cavity 40A depending on the metal material of the metal profile or the thickness dimension of a part of the metal profile in which the cavity 40A is formed. The filling ratio of the foaming resin material 51 with respect to the cavity 40A may be less than 50% or more than 60%.

The thermal insulating profile 1 according to the above-mentioned embodiments is used as, for example, a frame member and a stile member for various kinds of sash windows in a building, such as a double sliding window, a single sliding window, a casement window, an awning window, an inward swinging window, an outward swinging window, a double hung window, an inward opening window, and an outward opening window, and also used as a frame member for construction members, such as a door and a louver.

The disclosure can provide a thermal insulating profile that can employ a thermal insulating material formed from a foaming resin material, that can eliminate burden of finishing a surface part exposed from an injection port, and that can increase the number of variations of the finished state of the surface part.

Although the disclosure has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.

Claims

1. A thermal insulating profile, comprising:

a first profile portion made of metal;
a second profile portion made of metal;
a thermal insulating material made of a foaming resin material, the thermal insulating material being configured to couple the first profile portion and the second profile portion to each other;
an injection port formed, along a longitudinal direction of the thermal insulating profile, between the first profile portion and the second profile portion; and
a closing member disposed at the injection port to close the injection port.

2. The thermal insulating profile according to claim 1, wherein the thermal insulating material is formed of a foaming resin material having an expansion ratio of 3 to 5.

3. The thermal insulating profile according to claim 1, wherein

the first profile portion and the second profile portion each include a portion to hooked, and
the closing member includes a closing body portion disposed at the injection port and a hooking portion configured to be hooked to portions to be hooked of the first profile portion and the second profile portion.

4. The thermal insulating profile according to claim 3, wherein

the hooking portion includes engaging protrusions that are elastically deformable, and
the engaging protrusions include distal end portions provided with claw portions to be engaged with the portions to be hooked of the first profile portion and the second profile portion.

5. The thermal insulating profile according to claim 4, wherein

the hooking portion has a pair of the engaging protrusions,
a protruding length dimension of the pair of the engaging protrusions between the closing body portion and the claw portions is larger than a thickness dimension of the portions to be hooked of the first profile portion and the second profile portion,
a dimension from a surface of one of the pair of the engaging protrusions that faces the portion to be hooked to a surface of another of the pair of the engaging protrusions that faces the portion to be hooked is smaller than a width dimension of the injection port, and
a dimension between distal ends of the claw portions along a width direction of the injection port is larger than the width dimension of the injection port.

6. The thermal insulating profile according to claim 4, wherein the closing member includes a backing protrusion for the engaging protrusions, the backing protrusion protruding from the closing body portion.

7. The thermal insulating profile according to claim 6, wherein an air escaping groove is formed between the engaging protrusions and the closing body portion.

8. The thermal insulating profile according to claim 4, wherein

a part of the engaging protrusions that abuts on the portions to be hooked of the first profile portion and the second profile portion is formed from a soft resin material, and
the closing member is formed from a hard resin material except for the part formed from the soft resin material.

9. The thermal insulating profile according to claim 3, wherein

a part of the closing member that abuts on a portion to be hooked of one of the first profile portion and the second profile portion is formed from a soft resin material, and
a part of the closing member that abuts on a portion to be hooked of another of the first profile portion and the second profile portion is formed from a hard resin material.

10. The thermal insulating profile according to claim 1, wherein open cells that are continuous from an inner surface on a thermal insulating material side to an outer surface on an exterior side are formed in the closing member.

11. The thermal insulating profile according to claim 1, wherein

a cavity is formed between the first profile portion and the second profile portion,
the closing member includes an abutment piece portion configured to abut on the first profile portion or the second profile portion in the cavity, and
the abutment piece portion is configured to partition the cavity into a thermal insulating space in which the thermal insulating material is disposed and a hollow space.
Patent History
Publication number: 20180266752
Type: Application
Filed: Oct 11, 2017
Publication Date: Sep 20, 2018
Inventors: Ryuichiro Mizuno (Tokyo), Akiyuki Kuriyama (Tokyo), Tomoaki Eguchi (Tokyo)
Application Number: 15/729,809
Classifications
International Classification: F25D 23/06 (20060101); F25D 17/04 (20060101);