Window Sash Assembly Automation with Integrated Insulating Glass
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Solution Overview
Problem
The existing method for assembling window sashes with integrated insulating glass panes, known as the 'sashlite' method, is labor-intensive and prone to quality deficiencies due to manual operation, leading to high personnel costs and potential errors.
Innovation Solution
A mechanized method involving the setup of frames and glass plates in a vertical or inclined position, where a paste-like adhesive compound with moisture-binding material is injected between parallel webs, and a continuous sealing compound is applied, allowing for precise alignment and pressing of glass plates against the frame using suction devices and pneumatic thrust plates to ensure proper adhesion and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly method is used, then flexibility and adaptability are maintained, but productivity is low and quality consistency deteriorates
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated injection molding and pressing systems. The injection device automatically injects adhesive compound into the frame profile, and the pressing device automatically presses glass panes against the frame, eliminating manual labor and significantly increasing productivity while ensuring consistent quality through precise control of injection and pressing parameters.
Solution Approach 2:
The frame profile is designed with self-contained features including integrated adhesive injection channels, positioning ribs, and sealing grooves that guide the automated assembly process. The profile structure itself provides the pathways and positioning mechanisms needed for the injection and pressing operations, allowing the system to assemble without complex external tooling.
2Manufacturing precision
If manual assembly is used, then operational flexibility is maintained, but manufacturing precision and quality consistency deteriorate
Solution Approach 1:
The patent replaces manual alignment operations with automated positioning systems. The injection device precisely positions and injects adhesive at controlled locations, and the pressing device automatically aligns and presses glass panes against the frame with consistent force and positioning. This mechanical automation ensures uniform alignment precision across all assembled units.
Solution Approach 2:
The patent controls critical assembly parameters including injection pressure, injection volume, pressing force, and pressing duration through automated systems. These parameters are precisely controlled and replicated for each assembly cycle, ensuring consistent manufacturing precision. The frame profile geometry is also optimized with specific rib configurations and groove dimensions that facilitate precise alignment.
3Productivity
If automated injection and pressing systems are used, then productivity increases, but device complexity increases
Solution Approach 1:
The patent combines the adhesive injection function and the glass pressing function into a single integrated automated assembly system. The injection device and pressing device work in sequence as part of one automated cycle, reducing the need for separate manual operations and multiple independent devices. This integration increases productivity while managing overall system complexity through coordinated automation.
Solution Approach 2:
The frame profile design incorporates multiple functions into a single component: structural support, adhesive containment channels, glass positioning features, and sealing integration. This multi-functionality reduces the number of separate components and devices needed in the assembly system, managing complexity while enabling automated high-speed assembly.
4Reliability
If adhesive injection is performed manually, then process simplicity is maintained, but reliability and quality consistency deteriorate
Solution Approach 1:
The patent replaces manual adhesive application with an automated injection system that precisely controls adhesive dosage, placement, and distribution. The injection device delivers consistent amounts of adhesive to specific locations in the frame profile for each assembly cycle, ensuring reliable bonding. This automation increases reliability while the injection system is designed to be relatively simple, using basic pneumatic or mechanical actuation.
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 reduces personnel costs, enhances quality, and increases the operational life of the insulating glass pane by automating the assembly process, reducing errors, and improving productivity through horizontal conveyor systems and precise alignment techniques.
Implementation Method 1
holding by machine the two glass plates and the frame such that the two glass plates are located opposite each other
Implementation Method 2
pressing by machine the two glass plates against the webs facing them
Implementation Method 3
a paste-like adhesive compound, in which a moisture-binding material is embedded, is injected into the space between the two webs
Data Source
AI summary
A method for assembling a window sash having an integrated insulating glass pane. The window sash has a frame formed from plastic hollow profile sections. The frame has an inner face, an outer face facing away from the inner face, and two flanks that connect the inner face and the outer face to each other. On the inner face thereof, the frame has two webs parallel to each other, which constitute an all-round delimitation of the window opening of the window sash and are adhesively secured to two glass panes which are held spaced apart by the two webs.