Process for the manufacture of a profile for metal joinery having a thermal gap

A process for the manufacture of composite profiles of large dimension having a thermal gap, said profiles being composed of two thin metal profiles combined with a foamed plastic core, comprising providing a two piece mold, each piece of said mold having an internal face of generally L-shape in cross section, applying the two thin and flexible metal profiles of generally L-shape in cross section each onto a respective one of said internal faces, each L-shaped profile having a long branch and a short branch with each branch terminating in a free end, said profile being applied with the face end of a long branch of one profile adjacent the face end of a short branch of the other profile and with the free ends of the two profiles being separated by elastomer jointing integral with the shell, pressing the jointings between the corresponding edges of the profile, said jointing having an end base with a groove, and then injecting a foaming material between the two metal profiles at one end of said mold in which the long branch of the L is turned towards the exterior in a direction opposite to the small branch of the L, corresponding to an N-shaped section forming a rib followed by a groove which engages in the end groove in the jointing.