Profile Bending Machine for Insulating Glass with Thermal Control
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Solution Overview
Problem
Existing profile bending machines are inadequate for processing 'Warm Edge' profiles, which require heating and cooling, and cannot efficiently bend profiles with precise 90° angles without causing deformation or aesthetic issues, limiting their ability to handle different material types and resulting in increased processing time and breakage.
Innovation Solution
A dedicated computer-controlled profile bending machine with a universal top forming assembly and a novel heating and cooling system that allows for on-line heating and cooling of profiles, enabling precise 90° bending of aluminum and 'Warm Edge' profiles, both heated and unheated, with all necessary components integrated into the machine for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If 'Warm Edge' profiles with steel outer part and plastic inner part are bent using conventional profile bending machines, then the bending force required increases significantly, but the machine structure and processing capability remain insufficient
Solution Approach 1:
The patent applies parameter changes by heating the profile to alter its physical state and reduce stiffness. The heating system raises the temperature of the profile material, particularly the plastic inner part, to make it more pliable and easier to bend, thereby reducing the bending force required while maintaining structural integrity.
Solution Approach 2:
The patent implements preliminary action by heating the profile before bending. The heating step is performed in advance to prepare the material for bending, making it more ductile and reducing the force needed during the actual bending operation. This preliminary thermal treatment prevents machine overload and ensures smooth processing.
2Loss of time
If 'Warm Edge' profiles are bent without heating, then the processing time is reduced, but the profile deformation occurs and aesthetic quality deteriorates
Solution Approach 1:
The patent uses parameter changes by controlling the temperature of the profile during bending. By heating the profile to an optimal temperature range, the material becomes more ductile, allowing for precise bending at 90° angles without deformation. The controlled thermal parameter enables high manufacturing precision while maintaining efficient processing.
Solution Approach 2:
The patent replaces purely mechanical bending with a combined thermal-mechanical process. Instead of relying solely on mechanical force, which causes deformation, the patent introduces thermal energy to soften the material, making it more responsive to bending forces and achieving precise angles without aesthetic defects.
3Adaptability or versatility
If conventional bending machines process different material types, then operator-assisted assembly changes are required, but the switching time and operational complexity increase
Solution Approach 1:
The patent implements universality by designing a bending machine with a heating system that can process multiple material types including aluminum profiles and 'Warm Edge' profiles with different compositions. The heating capability makes the machine versatile, allowing it to handle various materials without requiring operator-assisted assembly changes, thereby reducing switching time and operational complexity.
Solution Approach 2:
The patent applies self-service by automating the material handling process. The machine automatically adjusts and processes different material types through its heating and bending system without requiring operator intervention for assembly changes. This automation eliminates manual switching operations and reduces downtime between different material processing tasks.
4Ease of manufacture
If aluminum profiles are used for spacer elements, then the processing simplicity and economic cost are improved, but the thermal insulating capability deteriorates
Solution Approach 1:
The patent addresses the thermal insulation issue by processing 'Warm Edge' profiles that are composite materials consisting of a plastic inner part and a steel outer part. These composite profiles provide improved thermal insulation compared to pure aluminum profiles. The patent's heating and bending process enables efficient manufacturing of these composite structures, balancing thermal performance with processing feasibility.
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
The machine simplifies the processing of various profile types, ensures precise 90° bending without deformation, and reduces processing time and breakage, while maintaining aesthetic quality, allowing for seamless switching between different material types without the need for operator-assisted assembly changes.
Implementation Method 1
a novel heating and cooling system that allows for on-line heating and cooling of profiles
Implementation Method 2
a novel heating and cooling system that allows for on-line heating and cooling of profiles
Data Source
AI summary
A computer controlled method for bending profiles for making insulating frames for double and triple glass pane glazings comprises at least the steps of: automatically feeding the profile to a profile machining section; immediately bringing the profile to a bending position, in which the profile is heated directly by hot air jets to a malleable condition at the bending position without moving the profile in its malleable condition.