Variable-Width Connector for Insulating Glass Spacer Frames
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Solution Overview
Problem
The production of spacer frames for insulating glass units requires multiple connectors of varying widths due to different pane thicknesses, leading to complexity and inefficiencies in automation.
Innovation Solution
A connector design featuring at least two support elements connected via a deformation element, such as a spring element, allowing adjustable width adjustment through deformation, which can be reversible, partially reversible, or irreversible, to accommodate different spacer frame widths without the need for multiple connector types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple connectors of different widths are used to accommodate different pane thicknesses, then the spacer frame can be adapted to various configurations, but the device complexity and number of connector types increase
Solution Approach 1:
The connector incorporates a deformation element that allows the width to be dynamically adjusted during assembly. The support elements can be elastically or plastically deformed to accommodate different distances between spacer frame ends, transforming a static connector into a dynamic one that adapts to various configurations without requiring multiple fixed-width connector types
Solution Approach 2:
The width parameter of the connector is made variable through the deformation element. By changing the deformation state of the support elements, the connector width can be adjusted to match different spacer frame configurations, effectively replacing multiple connectors with different fixed parameters with a single connector whose parameters can be modified
2Adaptability or versatility
If multiple connectors of different widths are maintained in inventory, then different spacer frame widths can be produced, but the loss of time for magazine changes and setup increases
Solution Approach 1:
A single connector design serves multiple functions by accommodating different spacer frame widths through deformation of the support elements. This universal connector can replace multiple specialized connectors in the inventory, allowing the production system to produce various spacer frame widths using the same connector type without requiring magazine changes
3Ease of manufacture
If the connector width is fixed during manufacturing, then the connector structure is simpler, but the adaptability to different spacer frame dimensions is reduced
Solution Approach 1:
The connector is segmented into distinct functional elements: support elements and a deformation element. The support elements provide the structural framework for connection, while the deformation element specifically enables width adjustment. This segmentation allows the majority of the connector to remain simple and easy to manufacture, while only a specific portion incorporates the complexity needed for adaptability
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 design simplifies automation by reducing the number of connector types needed, ensures secure fixation and sealing, and allows for efficient adaptation to varying spacer frame dimensions, enhancing production efficiency and consistency.
Implementation Method 1
The deformation can, for example, be completely reversible, partially reversible or irreversible. This can be achieved, for example, by an elastic deformation element, a partially elastic deformation element, or a plastically deformable deformation element.
Implementation Method 2
Plastic deformation has the advantage that any hindrance to the insertion process caused by springback can be avoided.
Data Source
Figure 1~3
Figure 4~6
Figure 7~9
AI summary
In a connector (1), it is therefore proposed to arrange a deformation element (14, 15, 16) held on both sides such that the width (8) of the connector (1) can be varied by deformation of at least one of the deformation elements (14, 15, 16). (cf. Fig. 1)