US 2019/0085617 A1Published application

Apparatus and method for assembly of structural profiles and resultant structures

AssigneeArconic Inc.

InventorsWilliam J. Hooper, Jr., Ion-Horatiu Barbulescu

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Abstract

A composite structure has a pair of parallel aluminum extrusions bridged by a polymer cap and defining a U-shape hollow. The hollow is filled with an expandable foam that adheres to and mechanically interdigitates with the extrusions, which have channels for receiving insertion legs of the extrusions and have extensions, which the foam encapsulates. End caps may be used to further delimit the hollow. The caps and the foam have a thermal conductivity less than that of the extrusions, providing a thermal break. An upper cap may be used and may incorporate features to compensate for the foam expansion. Excess foam may be trimmed. A forked tool may be used to hold the extrusions during joining.

Claims21

Dependent claims

A composite structure, comprising:

a first extrusion;
a second extrusion disposed adjacent the first extrusion with a space there between, each of the first extrusion and the second extrusion having a channel;
a cap extending between and joining the first extrusion and second extrusion and defining a three dimensional volume bounded by the first extrusion, the second extrusion and the cap, the cap being made from a material having a thermal conductivity less than that of the first extrusion and the second extrusion;
and
a foam fill at least partially filling the volume,
wherein the cap has a pair of insertion legs extending from opposing sides of the cap, each of the pair of insertion legs extending in the same direction,
wherein each of the channels is parallel with one of the pair of insertion legs, and
wherein the channels face toward the cap such that each of the pair of insertion legs insert into one of the channels, the channels having extensions along a length thereof extending in a direction distal to an insertion leg inserted therein, the extensions extending into the foam and having indentations, the foam interdigitating with the indentations.

5 more elements

A method for forming composite structures, comprising the steps of:

(A) providing a first extrusion and a second extrusion, each having at least one open channel extending along a length thereof;
((B) providing a cap having a pair of spaced insertion walls extending along edges of a web thereof;
(C) assembling the cap to the first extrusion and the second extrusion with the spaced insertion walls inserting into the open channels of the first and second extrusions and the web bridging between the extrusions, the elongated cap holding the extrusions in spaced relationship defining a volume with a U-shaped cross-section, the cap forming the bottom of the U-shape and the extrusions forming the sides of the U-shape;
(D) providing a pair of end caps bridging the first extrusion, the second extrusion and the elongated cap in a direction perpendicular thereto;
(E) applying a first end cap to one end of the first extrusion, the second extrusion and the elongated cap;
(F) applying a second end cap to a second end of the first extrusion, the second extrusion and the elongated cap;
(G) depositing a flowable foam into the volume, the foam spreading over the cap and extending between the first and second extrusions;
and
(H) allowing the foam to cure to a solid state.

6 more elements

Dependencies are inferred from the claim text.

Facts

Application: 15/705,958Filed 15 Sep 2017
Published: 21 Mar 2019
Term ends: Not estimatedThe source records don’t support an estimate.

Classification23 codes

E06B 3/26303
With prefabricated insulating strips between two metal section members: with thin strips, e.g. defining a hollow space between the metal section…
B29C 44/18
Incorporating or moulding on preformed parts, e.g. inserts or reinforcements: filling preformed cavities
B29C 44/334
Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements: filling the preformed spaces or cavities
E06B 1/18
Metal frames: composed of several parts with respect to the cross-section of the frame itself

Family

US 10,370,893 B2Related patent
US 2019/0085617 A1This patent

From the US filing history. Foreign family members aren’t listed.

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