Spacer Frame Corner Welding for Insulating Glass
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Solution Overview
Problem
Existing methods for producing rectangular spacer frames for insulating glass panes are complex, time-consuming, and result in an unstable connection at the corner areas, especially when using relatively thin-walled profiles, requiring long projections of corner connectors and complex sealing procedures.
Innovation Solution
The method involves mitering or cutting the frame pieces at their ends, allowing them to be pressed together and welded at the contact point, with corner connectors inserted to hold down the corner areas during welding, enabling a smooth sealing surface and efficient assembly of the spacer frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If frame pieces are mechanically plugged together with corner connectors, then assembly is simplified, but connection stability deteriorates
Solution Approach 1:
The patent combines mechanical plugging and welding into a hybrid connection system. Corner connectors are first mechanically inserted into frame pieces, then the assembly is welded to create a permanent bond. This merging of connection methods achieves both easy assembly (mechanical insertion) and high reliability (welded connection).
Solution Approach 2:
The connection system uses composite joining methods - combining mechanical fastening (plugging) with thermal processing (welding). The corner connectors and frame pieces are made of thermoplastic materials that can be both mechanically assembled and thermally bonded, creating a composite connection structure that leverages the advantages of both methods.
2Strength
If corner connectors have long projections to engage deeply in frame pieces, then connection strength improves, but device complexity increases
Solution Approach 1:
The patent merges mechanical engagement (short connector projections) with welding to achieve strong connections without requiring long projections. The welding process creates the primary bond strength, allowing corner connectors to have simpler, shorter geometries while maintaining connection strength.
Solution Approach 2:
The patent extracts the primary connection function from the mechanical plugging system and transfers it to the welding process. This allows the corner connectors to have reduced projection lengths since the welding, not the mechanical engagement, provides the main connection strength.
3Reliability
If plastic is sprayed to seal gaps between frame pieces and corner connectors, then sealing is achieved, but manufacturing time increases
Solution Approach 1:
The patent removes the separate sealing step (plastic spraying) by designing frame pieces and corner connectors with complementary mating surfaces that create inherent seals when assembled. The precision-fit interfaces between components provide sealing without requiring additional sealing materials or processes.
Solution Approach 2:
Instead of adding sealing material to gaps, the patent inverts the approach by designing the geometry of frame pieces and corner connectors to eliminate gaps in the first place. The mating surfaces are shaped to contact each other directly, creating seal surfaces through the component geometry itself rather than through added sealing layers.
4Reliability
If frame pieces are welded at corner areas, then connection stability improves, but risk of deformation increases
Solution Approach 1:
The patent performs preliminary mechanical plugging of corner connectors into frame pieces before welding. This preliminary action pre-aligns the components and distributes upcoming welding forces, preventing deformation during the thermal process. The mechanical connection acts as a scaffold that stabilizes the assembly before the welding heat is applied.
Solution Approach 2:
The corner connectors serve as intermediary elements between frame pieces during welding. They are mechanically inserted first to create a stable intermediate structure, then they remain in place during welding to distribute thermal stresses and prevent direct contact forces between frame pieces that could cause deformation.
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 simplifies the production process, ensures a stable and smooth sealing surface, and allows for the use of thinner profile frame members by distributing the welding force over a larger area, reducing the risk of deformation and seam formation during the welding process.
Implementation Method 1
the contact point of the two frame pieces is pressed together and the frame pieces are welded or fused at the point of contact
Data Source
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AI summary
The method involves arranging four scale pieces (3,4,5,6) between four scale corners. A corner connection is inserted into one of the scale pieces before an assembling the two scale pieces at one end and. A plug-in movement is sustained until the ends of the scale pieces are contacted with each other. A contact point of the both scale pieces is compressed and the scale pieces are welded at the contact point. An independent claim is included for a device for manufacturing a rectangle spacer scale for an insulating glass pane made of plastic.