The mainstream production process for thermal insulation strip insertion equipment for aluminum alloy profiles is the three-step method (roller-pressed embedding). A simplified two-step process also exists. The core is to complete the composite of aluminum alloy profiles and thermal insulation strips through toothing, strip insertion, and roll pressing. The specific process is as follows:
Mainstream Process: Three-Step Method (Traditional Standard Process)
This is the process commonly used in domestic production lines. The complete process flow is divided into three stages: pre-processing, core processes, and post-processing:
Pre-processing: The profile is placed on an operating platform (to inspect the surface quality and dimensional specifications of the profile) → a protective film is applied (to protect the profile surface from damage during processing).
Core Process:
Toothing: Using a toothing device equipped with hardened hobbing gears, serrated grooves are rolled into the inner wall of the groove where the thermal insulation strip is inserted into the aluminum profile. This increases the roughness of the profile, enhances the shearing force after subsequent composite bonding, and ensures a firm bond between the thermal insulation strip and the aluminum profile.
Threading: A threading machine accurately inserts PA66 nylon thermal insulation strips or rigid PVC thermal insulation strips into the pre-cut toothed grooves of the aluminum profile. The equipment uses toothed rollers to ensure threading accuracy and speed.
Rolling: A roll forming machine rolls the profile with the inserted thermal insulation strips, ensuring a tight bond between the aluminum profile and the thermal insulation strips. This ensures bonding strength and profile perpendicularity, a crucial step in guaranteeing product quality.
Post-processing: For foamed thermal insulation aluminum profiles, polyurethane foam is filled into the insulation cavity, followed by packaging for protection.
Optimized Process: Two-Step Method (Simplified Process)
To shorten process time, some companies have developed a two-step process that integrates the toothing and threading processes onto a single integrated toothing and threading machine. The subsequent roll forming process is still retained. The underlying principle is the same as the three-step method, but the integration of equipment reduces the number of steps, making it more suitable for small and medium-sized production capacities.
