Sharp Corner Forming Tools for Insulating Glass Spacers
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Solution Overview
Problem
Existing methods for forming spacers in insulating glass with deformable materials, such as thermoplastic, struggle to produce sharp-edged corners, which are preferred for aesthetic and insulation reasons, as they require precise adjustment of sealing compound and have inefficiencies in corner formation.
Innovation Solution
The use of tools with mirror-inverted effective surfaces placed on the lateral surfaces of the spacer to deform the corners into sharp-edged shapes, allowing for simultaneous or sequential formation of one or more corners, and integration with a nozzle system for in-situ application and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tools with mirror-inverted effective surfaces are used to deform corners, then corner sharpness and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The patent applies inversion by using tools with mirror-inverted effective surfaces that are placed on the lateral surfaces of the spacer. Instead of trying to form sharp corners directly from the extruded strand, the tools deform the rounded corners by pressing against them with surfaces that are mirror images of the desired corner geometry. This inverted approach allows the deformation process to achieve precise sharp-edged corners while using relatively simple pressing tools.
2Object-affected harmful factors
If corners are made sharp-edged, then heat insulation and aesthetic quality are improved, but sealing compound adjustment becomes more difficult
Solution Approach 1:
The patent applies preliminary action by forming the sharp-edged corners before the sealing compound is applied. The corner deformation process is completed on the spacer strand while it is still in place on the glass pane, creating the precise sharp-edged geometry needed for optimal heat insulation. This preliminary corner formation ensures that when sealing compound is subsequently applied, the amount required can be precisely controlled since the corner geometry is already finalized, eliminating the need for difficult adjustments later.
3Productivity
If deformable material is applied in-situ, then productivity is improved, but corner formation quality deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the corner formation process into distinct stages: first, the deformable material strand is quickly applied in-situ to the glass pane (maintaining high productivity), and then the corners are separately deformed using pressing tools to achieve sharp edges (improving corner quality). This segmentation allows the high-speed extrusion process to continue uninterrupted while corner formation is handled as a subsequent precision step, resolving the contradiction between production speed and corner sharpness.
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
Enables the production of sharp-edged corners in spacers made of deformable materials, optimizing the use of sealing compound and improving heat insulation by ensuring precise corner formation and adjustment, thus enhancing the quality of insulating glass production.
Implementation Method 1
the strand is located some distance ('recess') from the edge of the glass pane, i.e., is mounted offset inward relative to the edge of the glass pane. After the strand, which forms the spacer, has been applied, the beginning and the end of the strand are connected to one another, for example by the overlapping ends of the strand being compressed.
Data Source
AI summary
In order to produce sharp corners in edge regions (2) of a strand (1) of deformable material which is applied to a glass pane, the strand (1) forming a spacer in the insulating glass, a tool (5) is forced against the outer corner (3) and a tool (6) against the inner corner (4). The tools (5, 6) have active portions (7, 8) which correspond to the shape of the outer corner (3) and to the shape of the inner corner (4).