Issues encountered during the production of thermal-break aluminum and primary aluminum doors and windows
Release date:
2025-09-01
| Thermal-break aluminum doors and windows made from primary aluminum are a type of broken-bridge aluminum window system. Their architectural profiles represent a new generation of building materials designed to meet energy-efficient construction standards. Key advantages include exceptional rigidity, superior hardness and strength, excellent fire resistance, outstanding thermal insulation and heat-blocking performance, large daylighting areas, remarkable durability against atmospheric corrosion, an extended service life, and aesthetically pleasing decorative effects. Overall, these windows boast superior performance characteristics. Moreover, they are crafted by connecting primary aluminum profiles with non-metallic materials that have inherently low thermal conductivity, making them composite materials with both thermal and cold-insulation capabilities. In addition to the typical properties expected of architectural profiles, these windows also deliver exceptional thermal and soundproofing performance. “The cast thermal break technology” and “through-bolt insulated virgin aluminum profiles” are relatively complex in broken-bridge aluminum door and window technology and prone to errors. According to extensive experience and relevant process data: Pouring the thermal break Liquid insulation material is injected into the thermal break groove of the primary aluminum profile and allowed to cure. The temporary connecting bridge within the groove is then removed, effectively breaking the metallic link. Finally, the two separated sections of the primary aluminum profile are rejoined using the cured insulation material as the bonding agent. 1.1 Generally, insulating adhesive should not be poured into excessively cold profiles, as this can easily cause cracking during subsequent processing of the insulated profile. Therefore, it’s important to pay attention to the temperature of the aluminum material being poured—during production, the ambient temperature should be maintained between 18°C and 30°C, with relative humidity kept below 50%. 1.2 The surface of the insulation groove should be kept clean—absolutely free of dust, grease, and dirt, as these can significantly impair adhesion. 1.3 After pouring, bubbles may appear on the mixture, and moisture could be present in the pouring trough (indicating the mixture has been contaminated by water or very humid air). In this case, the pouring trough should be inspected. Alternatively, you can take some material directly from the material container and perform a test pour to determine whether the issue stems from the mixture being exposed to moist air. 1.4 After casting, pay special attention to stacking the profiles horizontally to prevent the molten material from flowing downward while it’s still liquid. Place supports between the profiles, ensuring these supports rest on rigid materials used as spacers between layers. Choose either wooden or aluminum supports based on the complexity of the profile design. Additionally, avoid placing the supports directly on the cast material to prevent the molten metal from sticking to them. During stacking, operators should carefully inspect the joined ends to ensure a secure, gap-free bond. Finally, always lay the profiles flat to protect lower-profile pieces from potential damage caused by dripping. 1.5 When cutting the thermal break, the thickness of the saw blade should be 75%-100% of the maximum required bridge width. During sawing, the temporary aluminum bridge must be completely removed, ensuring that the depth of the insulated adhesive removed does not exceed 1 mm. When cutting the metal temporary connecting bridge, avoid making cuts that are too deep. 2-piece strip-type thermal break primary aluminum profile Using high-density polyamide PA66 strips with excellent thermal insulation properties, or rigid PVC plastic strips processed through a continuous extrusion and rolling technique, aluminum and plastic are seamlessly integrated into a single unit. 2.1 Common Issues During Tooth Cutting: A batch of materials labeled A or B was fully processed with teeth due to an unnoticed deviation in the material's flatness. However, during the production of finished insulation materials, it was discovered that one side exceeded the specified tolerance, leading to immediate termination of the process. To prevent such issues, operators should carefully compare the lower surface of the profiles against the blueprint using a dial caliper during production. Additionally, team leaders and quality inspectors should jointly analyze any discrepancies to ensure problems are promptly identified and addressed. |
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