Cast Composite Aluminum Profiles

Composite aluminum profiles are new types of doors and windows and curtain wall building materials combined with aluminum alloy and polymer insulation materials. Through this combination, a heat-insulating sandwich is formed at the center of the aluminum alloy profile, thereby achieving the purpose of “insulation aluminum profiles”. Insulated bridge composite aluminum profiles are mainly used in both strip and cast type.

The strip-type composite aluminum profile is formed by connecting two parts of the aluminum profile with two heat insulation strips, so as to prevent the conduction of heat inside and outside the aluminum profile and achieve the purpose of energy saving. It originated in Europe and it is suitable for the construction of low-rise windows. This is the reason why it was born and survived in Europe. But its strength, process, cost, etc. are not ideal. The current standard insulation bar is PA66, which has two production methods: hard top and traction. The hard-top method has a tight structure and a good appearance but is relatively "brittle." The toughness produced by the traction method is good but the appearance is poor, and the side has a process depression. In order to pursue the appearance of beauty and precision, using PA66 nylon plus ultra-fine glass fiber is a common feature of foreign insulation bars (rarely use other materials). Due to the use of ultrafine glass fiber, the tensile strength is only 60N/mm, and it is expensive. The domestic PA66 plus ordinary glass fiber as the main direction of attack has achieved certain breakthroughs. However, some people use PA6, ABS (styrene-acrylonitrile-butadiene terpolymer), PP (polypropylene), shoddy. Some people even use general-purpose plastics such as PVC, which can only be used as non-structural materials, instead of engineering plastic PA66 to make insulation strips, and some use mineral fibers and stone powder that seriously affect environmental protection. The main raw material of PVC insulation strip is polyvinyl chloride resin. Due to its low strength, large coefficient of thermal expansion, and toxicity, the relevant authorities of the country have clearly stipulated that the use of PVC for the production of aluminum profile insulation strips is not allowed.

Casting compound aluminum heat insulation and energy-saving technology originated in the United States. Since the late 1930s of the last century, with the wide use of aluminum doors and windows, some American innovative door and window designers began to consider the problem of poor thermal insulation of aluminum profiles. Effectively solve the energy saving technology of aluminum profiles. In general, these techniques use a mixture of high-molecular polymers and aluminum profiles. The cast-in-place complex aluminum profile technology represented by American Yasong Company is formed by pouring and forming a polyurethane heat-insulating bridge to bond the inside and outside of the aluminum profile into a whole, so as to achieve the purpose of environmental protection and energy conservation. Its performance, process, cost, etc. are very ideal.

Now we will make the following comparative analysis of casting and wear strip composite aluminum one. Comparison of basic performance (a) strength polyurethane casting composite aluminum due to one-time extrusion, this reduces the process defects, plus a one-time polyurethane poured into the aluminum insulation tank, curing polyurethane thermal insulation bridge, Due to the high adhesiveness of polyurethane, the polyurethane heat-insulated bridge and the aluminum profile are completely integrated and do not need to be pressed together, so the strength of the aluminum material is high. The strength of the polyurethane itself is relatively high, and the cross-sectional area of ​​the heat-insulating bridge is large, so the strength of the cast-in-place heat-insulating bridge is greater than that of the stringer. In this way, the overall strength of the cast composite aluminum profile is greater than that of the stringer type.

The strip-shaped composite aluminum profile itself is formed through two extrusions, and then the heat insulation strip is inserted into the process slot of two aluminum profiles and then rolled. The internal structure of the material is changed, and stress is generated so that the overall strength of the profile is poor, and even obvious cracks are made to make it a waste product.

(B) Profile cross-sectional area Polyurethane casting composite aluminum structure compact, small and beautiful; wear strips of composite aluminum profile due to open teeth, rolling technology, its cross-sectional area is very large, looks bloated, hypertrophy.

(3) Compared with the same length of composite aluminum profiles, the profile drawing rate is higher than that of polyurethane casting. Due to the large cross-sectional area of ​​the sliver type, the weight/meter ratio is larger than that of the cast type. The rate is less than that of cast-type composite aluminum [about 13%], and the production of 1 square meter of doors and windows consumes about 1 kilogram more. The use of cast insulated aluminum profiles for doors and windows, saving 25 yuan per square meter cost of aluminum. If a door and window factory makes 10,000 square meters of doors and windows every year, it can save 250,000 yuan.

(iv) Plasticity (window) There are various kinds of doors and windows, and there are more and more shaped windows and doors. Making profiled doors and windows requires the plasticity of the profile to be better. Polyurethane cast compound aluminum profiles can be machined into doors and windows of any shape, including 360-degree arcs. Due to the insecure connection between the heat insulating strip and the aluminum profile, when the aluminum profile is greatly deformed, the heat insulating strip easily escapes from the connecting groove of the aluminum profile, so that its window shape is limited.

(5) The heat-insulating polyurethane casting compound aluminum profiles have performed satisfactorily in long-term tests and practices. In the case of outdoor -20°C, the room still maintains about 18°C. When wearing a strip type outside -20?c, the room is kept at 8?c. It can be seen that the pouring type is better than the string-type heat insulation.

(6) The aluminum part of the inside and outside two-color strip-type composite aluminum profiles is extruded twice. The inner and outer parts of the aluminum profile are separately treated on the surface, and then the two-color structure can be completed by opening the teeth, wearing the strip, and rolling. Casting two-color forming process: 1. The internal and external parts of the aluminum profile are treated separately. 2. Make the necessary connection, pouring, and cutting of the aluminum profiles.

two. The cost comparison of aluminum profiles is 20,000 yuan/ton for aluminum, 8,000 yuan/ton for PVC insulation, 30,000 yuan/ton for PA66 insulation, and 22,000 yuan/ton for polyurethane casting rubber. The density of aluminum is 2.7g/cm?, the density of PVC is 1.4g/cm?, the density of PA66 is 1.3g/cm?, the density of polyurethane is 1.2g/cm?, and the width of casting cavity is usually larger than the width of the cavity Small 0.8cm, generally the inner and outer wall thickness is 0.15cm, and the middle thickness is 0.12cm. Profile length is calculated as 600cm.

1. The cost savings for each type of cast aluminum bar over the strip type are:

Each aluminum material saves weight: 0.8cm×(0.15+0.12+0.12+0.15)×600cm×2.7g/cm?=699.9g=0.7kg Each aluminum cost saving: 0.7kg×20yuan/kg=14yuan / Root 2. The wear rate is:

The strip thickness is 0.2cm, the strip width is 1.5cm, and the length is 600cm. (1) The amount of PVC strip per aluminum strip is: (0.2 × 1.5) × 2 × 600 × 1.4g/cm × = 504g = 0.5kg per aluminum Profile PVC wear strip cost: 0.5kg × 8.00 yuan / kg = 4.00 yuan / root (2) The amount of wear per aluminum profile PA66: (0.2 × 1.5) × 2 × 600 × 1.3g / cm? = 468g = 0.47kg Each aluminum profile PA66 wearing cost: 0.47kg × 30 yuan / kg = 14.1 yuan / root 3. The amount of polyurethane is:

The amount of polyurethane for each aluminum profile: 1.1cm × 0.8cm × 1.2g/cm × × 600cm / root = 633.6g = 0.6336kg / root per piece aluminum polyurethane cost: 0.6336kg / root × 22 yuan / kg = 13.94 / Root 4. Cast aluminum profiles save more than PVC strips:

14 yuan/root - (13.94 yuan/root - 4.00 yuan/root) = 4.06 yuan/root 5. Cast aluminum profiles save more than nylon 66

14 yuan / root - (13.94 yuan / root - 14.1 yuan / root) = 14.20 yuan / root three. Equipment cost analysis:

1. Wear strip type composite aluminum production line price per set:

(1) Domestic equipment: approximately 200,000 yuan - 500,000 yuan.

(2) Imported equipment: Switzerland, Italy, etc., each set price: about RMB 1.6 million.

2. Casting compound aluminum production line price per set:

(1) Domestic equipment: "Lianshi composite aluminum polyurethane casting machine" produced by Dalian Lianshi Science and Technology Co., Ltd. Price per set: RMB 250,000 - RMB 320,000.

(2) Imported equipment: The price of each set of equipment produced by American Yasong Company: RMB 700,000 - RMB 1.4 million.

After the above comprehensive analysis, it is enough to prove that the overall performance of the cast insulation aluminum profile is better than the wear strip type. In fact, cast compound aluminum profiles are widely used throughout the world and have been used in the United States for more than 40 years. Since 1975, the number of insulated aluminum profiles produced using Asean casting technology alone in North America is as high as 1.95 billion meters or 142,396,415 tons. In the past two decades, most of the more prestigious buildings built or refurbished in various countries of the world have used the American Asun cast insulation technology. In 1990, when more than 100 floors of the Empire State Building in New York City celebrated its 60th birthday, the original 6,500-inch steel windows were all replaced with insulated aluminum windows made from Asan casting thermal insulation technology and raw materials. , "Asian Song" has become synonymous with "insulation and energy saving" of aluminum alloy doors and windows and curtain wall systems; in Japan, the low-interest loan door and window energy saving plan led by the Ministry of Construction and Industry of Japan is designated to be completed by pouring insulation technology. In South Korea and Japan, people can feel the existence of cast insulation technology at any time and place in venues, news centers, foreign-related hotels and other ancillary facilities of the World Cup, as well as residential and commercial buildings. Pouring heat insulation technology brings convenience, comfort, health and pleasant green ecological space to everyone.