Spacer Frame Corner Interlock for IGU Vapor Sealing
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Solution Overview
Problem
Insulating glass units (IGUs) face issues with atmospheric water vapor infiltration due to discontinuities at frame corners and inefficiencies in the manual operations involved in fabricating spacer frames, leading to production delays and scrap generation.
Innovation Solution
A spacer frame assembly with a substantially linear channel and connecting structure featuring tactile interweaving projections and holes, formed through a process involving stamping and roll forming of metal strips, which ensures a secure seal and efficient assembly by minimizing manual operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If corner keys or V-shaped notches are used to connect frame elements, then assembly is enabled, but vapor infiltration paths are created at the corners
Solution Approach 1:
The frame is divided into multiple frame elements that are connected at corners using corner keys. This segmentation allows for modular assembly while maintaining structural integrity and vapor sealing through properly designed connection interfaces between segments.
Solution Approach 2:
Corner keys are inserted into recesses or channels formed in the frame elements, creating a nested connection structure. This nesting ensures that the corner keys are securely held in place while maintaining continuous sealant coverage over the connection interfaces, preventing vapor infiltration paths.
2Adaptability or versatility
If manual operations are used for cutting, assembling, and sealing frame elements, then flexibility is maintained, but production efficiency decreases
Solution Approach 1:
Frame elements are pre-cut to specific lengths and pre-assembled with corner keys before the sealing operation. This preliminary preparation allows for automated or semi-automated assembly lines where components are ready for rapid installation, significantly increasing production rate while maintaining design flexibility.
Solution Approach 2:
Multiple manufacturing operations (cutting, corner key installation, and sealant application) are combined into an integrated process flow. This merging allows for streamlined production where frame elements are prepared and assembled in sequence, reducing handling time and increasing overall productivity.
3Manufacturing precision
If sealant is applied after frame assembly, then assembly precision is maintained, but sealant coverage at corners is reduced
Solution Approach 1:
Corner keys are installed in the frame elements before the sealant application step. This preliminary installation ensures that the corner connection structure is in place to guide and support uniform sealant distribution, preventing sealant deficiency at critical corner locations while maintaining frame alignment precision.
Data Source
Figure 1A~1E
Figure 2~3
Figure 2A
AI summary
A spacer frame assembly and method of assembly includes a substantially linear channel comprising two lateral walls and a base wall. The channel has first and second ends that when assembled, includes at least three sides and corresponding corners between each of said sides. The first end includes a connecting structure and the second end includes an opposite frame end. The opposite frame end has an opposite channel for receiving a nose portion of said connecting structure. The opposite channel includes stiffening flanges extending inwardly from the lateral walls relative to the channel. The connecting structure further includes a first aperture in the base wall comprising a first projection into the channel and the opposite channel comprises a second aperture in the base wall comprising a second projection into the channel. Wherein the first projection tactilely interweaves with the second projection when the spacer frame is assembled.