Vacuum Glazing Support Separation With Single-Granule Placement
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Solution Overview
Problem
Current methods for separating granular supports in vacuum insulated glazing are inefficient due to air flow affecting accuracy, leading to unwanted granules on the glazing surface, increasing inspection costs and prolonging production cycles.
Innovation Solution
A device comprising a base, vibrator, separation chamber assembly, actuator, and feed tube, where the actuator makes reciprocating movements to accurately separate and arrange supports, utilizing a sensor to ensure only one support is placed at a time, and a system for arranging supports on a glazing surface with a transmission section and control mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If compressed air is used to send granules through the feed tube, then the granules can be transported to the glazing surface, but the air flow affects separation accuracy causing unwanted granules on the glazing surface
Solution Approach 1:
The harmful compressed air flow is completely removed from the system. Instead, the patent uses a mechanical separation chamber with a vibrating screen and gravity-fed discharge mechanism to transport granules without any gas flow, thereby eliminating the source of separation inaccuracies while maintaining transportation functionality
Solution Approach 2:
A mechanical intermediary system consisting of a vibrating screen and gravity-fed discharge mechanism is introduced between the granule source and the glazing surface. This intermediary replaces the harmful compressed air with a controlled mechanical transport system that maintains separation accuracy throughout the transportation process
2Manufacturing precision
If inspection and additional arrangement of supports are performed to remove unwanted granules, then the quality of glazing surface is improved, but the production cycle is lengthened and production efficiency is reduced
Solution Approach 1:
The separation process is performed preliminarily and correctly the first time through improved mechanical separation in the separation chamber. By ensuring accurate separation before granules reach the glazing surface, the need for subsequent inspection and re-arrangement operations is eliminated, thereby maintaining high surface quality while preserving production efficiency
Solution Approach 2:
The separation system is designed to be self-correcting and self-regulating through the vibrating screen mechanism and gravity-fed discharge. The system automatically ensures proper granule separation and placement without requiring external inspection or intervention, thereby eliminating wasted time and maintaining high productivity
3Manufacturing precision
If multiple inspection and re-arrangement operations are performed, then unwanted supports are removed, but the inspection cost increases
Solution Approach 1:
The patent converts the potential harm of granule misplacement into a benefit by designing a separation chamber with a vibrating screen and controlled discharge mechanism that proactively prevents misplacement from occurring in the first place. This preventive approach transforms what would have been a costly inspection and correction problem into a simple, low-cost mechanical separation solution
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
The solution enhances the accuracy and efficiency of support separation and arrangement, reducing unwanted granules and production costs by ensuring precise placement of supports, thus improving production efficiency.
Implementation Method 1
a vibrator (11), a separation chamber assembly (7)... The vibrator is provided on the separation chamber assembly
Implementation Method 2
The separation chamber assembly is inclinedly arranged with respect to a horizontal plane... the accommodation cavity is communicated with the dispensing outlet via the recess of the separation actuator
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
Provided is a device for separately arranging supports for vacuum insulated glazing and a method. The device for separately arranging supports for vacuum insulated glazing includes a base (1), a vibrator (11), a separation chamber assembly (7), a separation actuator, a feed tube (8), and a drive device. The drive device is provided at a side of the base and connected to the separation actuator, and the separation chamber assembly, the separation actuator, and the feed tube are provided at another side of the base. The vibrator is provided on the separation chamber assembly. The separation chamber assembly is provided with a feed inlet, an accommodation cavity, and a dispensing outlet. The feed inlet is communicated with the accommodation cavity. The dispensing outlet is communicated with the feed tube. The separation chamber assembly is inclinedly arranged with respect to a horizontal plane. The separation actuator passes through the separation chamber assembly, and is provided at a lower portion of the accommodation cavity in a reciprocatingly movable manner. An upper edge of the separation actuator at a side close to the dispensing outlet is provided with a recess capable of accommodating one support. During reciprocating movements of the separator actuator, the accommodation cavity is communicated with the dispensing outlet via the recess of the separation actuator. When the device is arranging supports, one reciprocating movement of the separation actuator can only transport one support, thereby eliminating the case in which multiple supports are arranged in one operation.