Energy efficient window frame profiles and thermoplastic reinforcements

aluplast and BASF jointly present energy efficient window frame profiles with thermoplastic reinforcements, presently the best combination of thermal insulation and cost effectiveness for window systems.

aluplast, a German window system manufacturer, is launching a new window system that is highly thermally insulated as well as cost effective, thanks to a version of Ultradur* High Speed (PBT) which BASF developed especially for this company. This glassfiber reinforced thermoplastic replaces the steel that is normally used for window frame profiles, thus providing much better heat insulating features without changing the mechanical properties of the windows. The new profiles do not only save time consuming and costly work steps for window manufacturers but also weigh 60 percent less than their predecessors containing metal. In early April, aluplast will be introducing this product innovation at the international trade fair “fensterbau/frontale 2008” in Nuremberg, Germany. The new window profiles will already be available on the market by that time. They can be processed on conventional production lines.

Getting rid of another thermal bridge
The metal reinforcement in conventional window frame profiles (on the right, in red) has always created a thermal bridge and thus a problem for the thermal insulation of buildings. Moreover, until now, window manufacturers themselves had to incorporate the metal profiles into the PVC profiles, thus having to allocate consider¬able resources to steel purchasing, steel logistics and manual steel processing. Now, aluplast offers window frame profiles that completely do without metal profiles. Instead, two flat plastic strips take over the task of reinforcing the profile (on the left, in black). The frame profile is lighter in weight, its thermal insulation capac¬ity (U-value) is markedly improved and window manufacturers no longer have to work with steel. See photo at right for detail.

Thermal insulation improved by 20 percent – thanks to plastics
Two flat strips made of Ultradur are extruded into the new window profile, replacing the metal profile that is usually heavy and difficult to install. “The high thermal conductivity of the metallic reinforcement used so far in the window frames has always resulted in a thermal bridge,” explains Manfred Wust, head of systems engineering at aluplast. “This is why we joined forces with BASF in the search for a material that would make the window frame as stiff as if it contained metal. At the same time, however, the material was supposed to have better insulating characteristics and contribute to greater energy efficiency in construction.” The U-value (formerly “k-value”: heat transfer coefficient, thus a parameter for thermal insulation capacity) of the window frame profiles using the flat Ultradur strips is improved by about 20 percent, namely, to 1.1 W/(m² . K), in comparison to the standard versions that contain a steel profile.

PBT instead of metal: light, firm and securely anchored
“Thanks to its extraordinary mechanical features within a wide temperature range, its dimensional stability and its low coefficient of expansion, this plastic is very well suited for use in window frame profiles,” states Dr. Kay Brockmuller of applications development at BASF Plastics. The Ultradur strips are optimally positioned and permanently anchored in the plastic profiles by means of extrusion. The flat plastic strips also ensure that the window frame profiles are 60 percent lighter in weight, which makes transport and installation easier as well.

In its new window frame profiles, aluplast has now replaced the metal reinforcement (left: in red) with considerably lighter strips made of BASF’s plastic Ultradur High Speed (right: in black). This has improved the thermal insulation capacity of the frame profile by about 20%. Additionally window manufacturers can now dispense with the labor-intense and expensive handling of steel. See photo at right for detail.

In addition – more service for window manufacturers
Window manufacturers can process the new profiles on their current equipment without the need to make additional investments. aluplast extrudes the plastic strips directly into the window frames, thus saving window manufacturers the laborious and expensive steps of steel purchasing, steel logistics and manual steel processing. “The new system is not earmarked as a special niche product; over the long term, we plan to switch over all of our profile systems, thus offering our customers a clear-cut competitive edge. We will start with the market launch of the new product in our large IDEAL 4000** profile line,” explains Manfred J. Seitz, owner of aluplast.

Ultradur is BASF’s brand name for its partially crystalline, thermoplastic, saturated polyesters on the basis of polybutylene terephthalate (PBT). They are used as materials in the production of high quality technical parts in many sectors of industry such as automotive construction and electrical engineering. Additional information about Ultradur can be obtained by calling phone no. [+49] (0) 621 60 78780.

The aluplast group is one of the largest and most innovative international manufacturers of plastic window systems. Today, its brand ranks third in a European brand comparison and seventh worldwide. This year, aluplast is commemorating its 25th anniversary of its founding, having become a global player within a quarter of a century. The aluplast group currently has 22 production sites and sales offices worldwide, with its customers numbering 1600 companies. Using aluplast’s annual production volume of 150,000 metric tons of PVC (for the extrusion of window systems), their customers manufacture 12 million windows per year. Thanks to their strict product policy, their cooperation with partner companies, their flexibility and market-oriented innovations, company owner Manfred J. Seitz and his sons Dirk and Patrick have succeeded in creating one of the most successful companies in the sector within just a few years.

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