Plastic Profiled Elements Beadless Sealing Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing processes for windows and doors, particularly those with plastic frames, face issues such as non-homogeneous sealing areas leading to excessive material melting and bead formation, complex and costly machinery, and labor-intensive manual glazing operations, which increase production time and costs.
Innovation Solution
A process that involves mechanical machining by chip removal to form grooves in the profiled elements before sealing, allowing for a beadless sealing method and simultaneous insertion of the inner panel into longitudinal slots, reducing the need for subsequent finishing processes and simplifying the glazing operation by using a system with integrated chip removal means and support assembly for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sealing is performed by melting head surfaces of profiled elements, then the profiled elements are sealed together to form frames, but excessive sealing bead is formed requiring costly and time-consuming removal processes
Solution Approach 1:
The invention performs preliminary machining of the profiled elements to create containing compartments and guiding grooves before sealing. This preliminary action prepares the surfaces to contain the molten material during sealing, preventing bead formation from the outset rather than requiring post-sealing removal
Solution Approach 2:
The invention converts the potentially harmful excess molten material that would form unwanted beads into a beneficial contained flow within the prepared compartments. The molten material is redirected to fill voids and create uniform seals rather than protruding as defects
2Shape
If finishing systems are used to remove sealing bead and clean sealing areas, then aesthetic appearance is improved, but processing time and equipment costs increase significantly
Solution Approach 1:
The containing compartments and guiding grooves are machined into the profiled elements before sealing occurs. This preliminary preparation ensures that when sealing happens, the molten material is automatically contained and directed, eliminating the need for subsequent bead removal operations
Solution Approach 2:
The invention extracts the bead removal function from the process by preventing bead formation in the first place through preliminary surface preparation and containment structure creation, rather than adding a separate removal step
3Reliability
If manual glazing operations are performed to insert inner panels into sealed frames, then proper installation is achieved, but labor costs and production time increase
Solution Approach 1:
The invention merges the sealing operation with the inner panel insertion operation into a single integrated step. The guiding grooves and containing compartments are designed to simultaneously achieve proper sealing and guide the inner panel into its final position, eliminating the need for separate manual glazing operations
Solution Approach 2:
The structure of the profiled elements with their integrated containing compartments and guiding grooves enables the system to self-guide the inner panel during insertion. The geometry of the components themselves provides the alignment and positioning functions that would otherwise require manual intervention
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more efficient, cost-effective, and simplified manufacturing process for windows and doors, eliminating the need for bead removal and manual glazing, thereby reducing production time and costs while maintaining a high-quality finish.
Implementation Method 1
The sealing of the profiled elements takes place by means of melting of respective head surfaces which is obtained by heating the portions to be connected by means of suitable plates with heating elements
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A process for the manufacture of windows/ doors, characterized by the fact that it comprises the following steps: • - providing at least one inner panel for windows/doors; • - providing a plurality of plastic profiled elements (3) for windows/ doors, each of the profiled elements (3) comprising at least two areas to seal (5), coupleable to the areas to seal (5) of the other profiled elements (3), and at least one longitudinal slot (6), in which a respective perimeter side of the inner panel is insertable; • - performing a step of mechanical machining by chip removal on at least one of the areas to seal (5); • - heating the areas to seal (5); • - coupling the heated areas to seal (5) to one another by pressing the profiled elements (3) one against the other to maintain the areas to seal (5) in mutual contact and define the frame for windows/doors, the coupling taking place with the inner panel inserted in the longitudinal slots (6) to define a window/door which is composed by the frame and by the inner panel contained in the frame. A system for implementing this process is also disclosed.