Spacer Frame Rising Locking Member Hermetic Seal
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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 production processes, leading to vapor leakage and increased scrap generation.
Innovation Solution
A spacer frame assembly with a rising locking member, featuring a linear channel with nested undulations and a tab stiffener for anti-buckling strength, is fabricated using a production line process that includes stamping, roll forming, and sealant application to ensure a hermetic seal and efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional corner joining methods (V-shaped notches or corner keys) are used to form frame corners, then the frame can be assembled, but discontinuities create infiltration paths for water vapor and reduce sealant effectiveness
Solution Approach 1:
The frame is divided into modular sections with standardized corner connectors that create continuous sealing surfaces. The corner keys are segmented into insertable components that fit into recesses, allowing the sealant to form an unbroken barrier across corner joints while maintaining structural integrity.
Solution Approach 2:
The corner key insertions create nested structures where one frame element is inserted into another at corner joints. This nesting arrangement allows the sealant to envelop the joint interface completely, eliminating infiltration paths while keeping the corner structure relatively simple and manufacturable.
2Productivity
If manual operations are used for frame assembly and sealant application, then flexibility is maintained, but production rates are limited and scrap generation increases
Solution Approach 1:
Corner keys are pre-formed and pre-positioned on frame elements before final assembly. Sealant application points are pre-prepared with alignment features and access channels. This preliminary preparation enables automated or semi-automated assembly lines to operate at higher speeds without sacrificing precision or increasing scrap rates.
Solution Approach 2:
The frame design incorporates self-aligning features and self-sealing mechanisms where the corner key insertions automatically create proper sealant distribution paths. The structure guides the sealant application process, reducing the need for complex manual operations and enabling more efficient automated manufacturing while maintaining low scrap generation.
Data Source
AI summary
A spacer frame assembly and method of manufacturing that includes a substantially linear channel comprising two lateral walls connected by a base wall, the channel having first and second ends that when assembled, includes at least three sides and corresponding corners between each of the sides; the linear channel further includes a nose portion of the first end and a receiving portion of the second end having a channel for receiving the nose portion; and the nose portion comprising a first undulation in the first end and the receiving portion comprising a second undulation in the second end. The first and second undulations nest when the ends are in an assembled position.