Thermal break aluminum profile production line

Thermal break aluminum profile production line

Thermal break aluminum profile production line is applied for producing thermal break aluminum profiles, including 4 sets of machines:  knurling machine, strip insertion/assembly machine, rolling machine and shear tester.

Why thermal break aluminum profile

As thermal break aluminum profile has the following advantages and it is widely used in the window and doors and curtain wall projects

1 Remarkable energy-saving effect, energy saving can be 30-40%

2 excellent sound insulation performances, can reduce noise 30-50Db.

3 superb anti-frosting and antifogging performance, the window can be clean and bright

4 High strength, wind resistance performance can be No.1 level standard

5 Good airtight and watertight performances, both is No.1 level standard

6 Three-chambered design principles, high stability structure, excellent mechanical properties.

7 Advanced strip feeding technology, with reasonable structure, firm combination, good rigidity features, heat insulation effect is better

8 Can be anodized, electrophoresis, powder coated and fluorocarbon coated, rich varieties, good performance, ideal energy-saving and sound insulation effect.

Thermal break aluminum profile production line machine function

Knurling machine 

Knurl the notch of aluminum profile, making teeth for strip inserting in one piece of aluminum profile.

Knurling step is very important, providing mechanical surface condition of aluminum extrusions, enhancing shear strength and making thermal barrier aluminum profiles stable and long service life.

Strip insertion/Assembly machine

The main work is inserting a thermal barrier polyamide strip in the notch of aluminum profile, and two pieces of aluminum profiles will be connected by the polyamide strip.

Rolling machine

Adopting microcomputer PLC touch screen control, rolling machine make aluminum profiles with strips rolled, the strips of aluminum profiles will be locked and the assembly will be finished.

Tester 

Test the shearing force of thermal break aluminum profiles (length 100mm) after rolling and assembly, check whether the strength is up to standard and the required value.

Thermal break aluminum profile production line features

High efficiency, energy-saving, low consumption, and the output of a single machine have been greatly improved compared with the current imported equipment. 

1. Knurling and strip insertion/Assembly machine can be in one same equipment, save one process;

2. The special design of the rolling wheel of the rolling machine ensures that the two sets of profiles are compounded and reliable;

3. The most precise sensor is applied and the test is accurate;

4. Use a reliable motor, frequency converter, reducer and other standard components;

5. The auxiliary frame is flexible and adjustable, and the whole set of equipment is digitally displayed;

6. It is an ideal equipment for processing high-quality thermal break profiles.

What is the difference between strip feeding and injection thermal break aluminum profile?

Strip feeding thermal break aluminum profile and injection thermal break aluminum profile difference

Injection process heat insulation technology is originated from the United States, whose function is injecting a mixture that is similar sealing wax into the aluminum extrusion of windows and doors for heating insulation.

The strip feeding process makes two parts of the inside aluminum extrusion profile and outside aluminum extrusion profile fit together so prevent heat conduction to achieve energy-saving purposes.

The injection process and strip feeding process of aluminum profile is featured with lightweight, high strength, good rigidity, sealed waterproof and sound insulation, long use life, etc.

It can significantly reduce heat exchange, have a good insulation performance and get energy-saving insulation and good environmental protection effects, which is the development trend of energy-saving and green building aluminum profiles.

Here are some differences between injection thermal break aluminum profile and strip feeding thermal break aluminum profiles:

1. Injection process and strip feeding process comparison

The injection process means making the surface-finished aluminum extrusion profile linear movement by running gear.

When the heat-insulating groove of the aluminum profile passed by the lower of the injection machine head, the liquid insulating materials will flow into heat-insulating grooves, after some times solidification, then cut the bridge.

Strip feeding process

Strip feeding thermal break aluminium profile has knurling, strip feeding and rolling three steps.

The knurling: to knurl the notch of aluminum extrusion by hard rolling gear, making teeth in both aluminum profiles

Strip feeding: feed strip into aluminium profiles, make the outside and inside aluminium profiles fit together for the following rolling process.  One set of strip feeder is ok

Rolling: Have guide and pre-clamping, clamping and strengthening (vertical and horizontal directions) processes, rolling forming machine make the aluminum profiles with thermal barrier rolled, having the compound function.

The rolling is the key factor in whether the product is up to standard, setting the high-pressure alarm and low-pressure alarm.

2 Different heat insulating materials

The injection process’s heat-insulating material is based on polyurethane insulating glue.

For the composition, in general, it is made up of resin components and isocyanate.

It is classified into domestic and foreign categories. 

The representative foreign injection material is US Azon, the material is from US or Korea. 

The typical domestic injection material is in Dali.

The strip feeding process’s heat-insulating material is the insulating barrier. 

Now the standard heat insulating strip is polyamide66 (commonly known as NYLON66).

In order to get surface appearance and precision, it is a common feature for the foreign insulating strip that is produced with PA66 nylon and fine glass fiber. 

Since superfine glass fiber is used in the production, so the tensile strength is only 60N/mm and the price is very expensive.

3. Production equipment

The injection process is one technology the machine and insulating glue is inextricable, so the equipment supplier and insulating glue supplier are the same.

The typical imported equipment is US Azon, the equipment cost is more expensive. 

For the domestic-made equipment, make the major changes based on the same function and the cost is more competitive in the market.

Strip feeding equipment can be imported equipment and domestic-made equipment, the imported equipment is from Germany or Switzerland, the domestic-made machine can be offered by many manufacturers and there are many choices for the customers. 

The whole line includes a knurling machine, strip feeder, rolling machine and tester.

4 Thermal barrier aluminum extrusion profiles

The injection process thermal break the aluminum profile, as it is extruded one time, minimum the process defects, inject polyurethane into the insulation groove of aluminum profiles once, and knurl to form a polyurethane insulating bridge.

As polyurethane has high adhesiveness, the thermal bridge and aluminum profiles will be completely whole, so the aluminum profile can get high strength.

Strip feeding thermal break aluminum profile, two pieces of aluminum extrusion profiles, feed the insulating strip into the groove of aluminum profiles, then rolling process.

The profile needs to be knurling, strip feeding and rolling and testing.

After that, the whole process is completed and the strip feeding thermal break aluminum profile is widely used in window and door, curtain wall projects.

 5 Thermal break aluminum profile cost

As the aluminum profile price is the same, the price of the PVC insulation strip and PA66 insulation strip is different, the injection polyurethane glue is different too.

So Injection process thermal break aluminum profile and strip feeding thermal break aluminum profile cost will be a little bit different and we can analyze the cost based on the specific profiles.

Here are the general differences between strip feeding and injection thermal break aluminum profiles.

How to make a thermal barrier aluminum profile

How to make a thermal barrier aluminum profile

You may wonder how to make the thermal barrier aluminum profile in the extrusion factory.

Here we show the story behind it and the steps for this brilliant product.

How to make a thermal barrier aluminum profile? 

All you need are aluminum profiles, a thermal break aluminum profile production line and a polyamide strip. 

Here thermal barrier aluminum profile is strip feeding method thermal insulating profile, not injection thermal barrier aluminum profile. 

What is the thermal barrier aluminum profile?

Two pieces of aluminum profiles are connected by a polyamide strip.

Aluminum can transfer heat or cold very easily, its thermal conductivity is high.

But polyamide strip’s thermal conductivity is very low, and then can block the heat or cold transfer through aluminum.

The raw material of the polyamide strips is nylon and glass fiber.

Thermal break aluminum profile assembling machine

The thermal break aluminum profile assembling machine is used for producing thermal barrier aluminum profiles, including four sets of machines:  knurling machine, strip insertion/assembly machine, rolling machine and shear tester.

Thermal barrier aluminum profile production process

The production process for thermal barrier aluminum profiles is as follows:

Load Aluminum profiles on the working platform →film sticking →knurling→ strip feeding→ rolling→ or feed polyurethane foam into the insulation chamber→ packaging

1  The first process

Test the surface quality and dimension tolerance of aluminum profiles, inner and outer aluminum profiles can be anodized or electrostatic powder-coated treatment,  also can be a different color.

Through the thermal bridge connection, the inside and outside two colors aluminum profiles for window and door can be got.

2 The second process

Stick protective film. The main function is to protect the surface quality of aluminum profile in processing and moving.

3 The knurling

It is the key process, make two inner walls of aluminum profiles rolled for jagged teeth.

Feed the strip into the teeth channel of aluminum profiles, compound them together.

Teeth channel depth is not specified in the Domestic market.

But in the industry standard for GB/T building thermal break aluminum alloy standard, there is a specification for the tensile strength and shear strength.

4 Strip feeding and rolling processes

Strip feeding is to feed EPDM strip into the teeth channel of aluminum profile.

Then through the rolling machine, make the aluminum extrusion profiles and Ethylene-Propylene-Diene Monomer o other materials strip rolled together

5 Shear test

Thermal barrier aluminum profile needs to meet the requirements of GB/T5237-2017, thermal barrier aluminum profiles also need to be tested for conventional shear strength and transverse tensile strength and combined elasticity.  

Take (100±1)mm long composite heat-insulating aluminum profiles, store it for two days at (23±2)℃ and humidity of 45%～55%, and use the shear strength tester to evenly push the force towards aluminum profile section, feed speed is 1～5mm/min, record applied load and corresponding shear deformation.

6 Packaging 

It can be packed by plastic bag or wrapping packaging by paper. 

The main function is to avoid damage and scratches in the transportation and processing.

Brightstar thermal barrier aluminum profile making machine features

High efficiency, energy-saving and lower power consumption, high production output

Knurling and strip feeding can be done in one set of machines.

The whole equipment can make two groups aluminum extrusion profile combined by 2 sets of knurling machines.

Special design for the roller of the rolling forming machine can ensure the stable combination of 2 pieces aluminum profiles.

Adopting the most precise sensor, the test accurately

Using the reliable quality motor, frequency converter and reducer standard components

Flexible and adjustable auxiliary frame, digital display

The stable quality, reliable performance, simple operation, it is an ideal equipment for heat insulation aluminum profiles.

How to make a thermal barrier aluminum profile? 

Follow our steps and it is such simple!

Load aluminum profiles on the working platform →film sticking →knurling→ strip feeding→ rolling→testing → packaging.

Contact us now to get a no-obligation quote on thermal break aluminum profile production!