Triple-Glazed Unit Offset Spacer Frames
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Solution Overview
Problem
The existing methods for manufacturing triple-glazed insulating units with multiple spacer frames and glass sheets face challenges in maintaining consistent adhesive layer temperatures, leading to uneven seal thickness and adhesion issues due to heat distribution limitations.
Innovation Solution
The solution involves offsetting the spacer frames relative to each other, with one frame being smaller than the other, to ensure equal exposure to heating elements and create a peripheral groove between the sheets, allowing for a filler material to be used, which helps in achieving consistent adhesive flow and seal formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heating oven temperature is increased to heat the inner adhesive layers, then the inner adhesive layers reach acceptable temperature, but the outer adhesive layers become overheated and pressed to thickness outside the desired range
Solution Approach 1:
The spacer frame is segmented into two distinct portions: a first portion with a first adhesive layer and a second portion with a second adhesive layer. This segmentation allows each adhesive layer to be positioned at different distances from the heating element, enabling independent temperature control and preventing the overheating of outer adhesive layers while ensuring adequate heating of inner adhesive layers.
Solution Approach 2:
Different portions of the spacer frame are designed with different thermal exposure characteristics. The first adhesive layer is positioned closer to the heating element for more direct heating, while the second adhesive layer is positioned farther away for indirect heating through the glass sheet. This local differentiation in thermal quality allows each adhesive layer to achieve optimal curing temperature without excessive heat exposure.
2Manufacturing precision
If the heating oven temperature is decreased to protect the outer adhesive layers, then the outer adhesive layers maintain desired thickness, but the inner adhesive layers remain underheated and fail to achieve proper adhesion
Solution Approach 1:
The spacer frame is divided into two portions with adhesive layers positioned at different thermal zones. This segmentation enables the outer adhesive layer to be protected from excessive heat while the inner adhesive layer receives sufficient heat through direct exposure to the heating element, ensuring both thickness control and proper adhesion.
Solution Approach 2:
The glass sheet acts as a thermal intermediary between the heating element and the second adhesive layer. It conducts heat to the second adhesive layer positioned on its inner surface, ensuring adequate heating for adhesion while the first adhesive layer positioned on the outer surface of the spacer frame receives direct heat for proper curing.
3Ease of manufacture
If the spacer frames are positioned directly aligned, then the manufacturing process is simplified, but the adhesive layers experience uneven heat distribution leading to inconsistent seal thickness
Solution Approach 1:
The spacer frame is designed with asymmetric positioning of adhesive layers relative to the glass sheet. The first adhesive layer is applied to the outer surface of the spacer frame while the second adhesive layer is applied to the inner surface, creating an asymmetric thermal exposure pattern that ensures even heat distribution across all adhesive layers and consistent seal thickness.
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 ensures that all adhesive layers are heated uniformly, resulting in the desired seal thickness and adhesion properties, improving the longevity and performance of the insulating unit by maintaining the integrity of the seal.
Implementation Method 1
The subassembly is conveyed though a heated oven between upper and lower heating elements to heat the adhesive to make it malleable
Implementation Method 2
the triple glazed subassembly passes between pressing rolls to bias the sheets toward one another against the spacer frames to form a moisture impervious seal having a desired thickness
Data Source
Figure 1~2
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Figure 6~7
AI summary
An insulating unit includes a first spacer frame between first and second sheets, e.g. glass sheets, and a second spacer frame between the second sheet and a third sheet. A first surface of the first spacer frame is adhered to inner surface of the first sheet, and an opposite second surface of the first spacer frame is adhered to a first surface of the second sheet, by a moisture impervious adhesive layer. A first outer surface of the second spacer frame is adhered to a second surface of the second sheet, and an opposite second outer surface of the second spacer frame is adhered to an inner surface of the third sheet, by the adhesive layer. The first spacer frame and the second spacer frame have an offset of greater than zero.