Discussion on the technological process of producing 50mm ultra-large spacer insulating glass.

1. The Introduction

The common sizes of hollow spacers are 6mm, 9mm, 12m, 16mm, and 20mm. The bendable spacers of these specifications can be automatically bent by a frame folding machine, filled with a full sub-sieve by a desiccant sieve filling machine, and coated by an automatic butyl rubber coating machine. Coated with automatic butyl rubber coating machine. The performance and efficiency guarantee of spacer insulating glass exceeding this specification is different from that of ordinary spacer insulating glass. This article mainly takes a 50mm wide spacer as an example to introduce the processing technology control of large-size and super-large-size spacer insulating glass, to provide a reference for insulating glass manufacturers who have this kind of large-format insulating glass processing.

2. The process flow

2.1 Cutting of oversized spacers

According to the size of the glass, the size of the sealing depth, and the thickness of the aluminum strip, the required size of the aluminum strip is calculated and cut. Its calculation formula is glass size - sealing depth - aluminum strip thickness = spacer length. The cutting saw should be cut with alcohol, not oil, to avoid obvious stains after the aluminum strips are combined. Pay attention to wearing gloves when taking and placing the aluminum strips during cutting, and avoid the surface of the aluminum strips from being oxidized and discolored by fingers touching the surface of the aluminum strips. After cutting each aluminum strip, use a brush to clean the surface aluminum scraps, and make a spacer between the aluminum strips to prevent scratches between the aluminum strips. When packing the aluminum strips, do not let the tape surface touch the front of the aluminum strips, and use spacers such as cardboard to separate them to avoid tape marks on the front of the aluminum strips.

2.2 Aluminum spacer bar assembly

The 50mm aluminum strip exceeds the size of the automatic frame folding machine and requires the use of gusseted frames. From the performance point of view, the joints of the corners of the gusseted frame are the main moisture penetration path, accounting for 70% of the total moisture penetration.

Table 1 Comparison of water permeability of glass in the gusseted frame and folded corner frame

The water vapor transmission rate and gas transmission rate of butyl glue are low, so the performance that can be achieved by continuous bending can be achieved by using butyl glue to seal the corner joint, see Figure 1, Figure 2, Figure 3, Figure 4.

Table 2 Sealant performance comparison

^{Figure 1 The corner insert is sealed with insulating glass butyl rubber sealant}

^{Figure 2 The aluminum strip is inserted into the insert}

^{Figure 3 Use butyl rubber to seal the seam} 

^{Figure 4 Use butyl rubber to seal the back of the joint}

2.3 Filling the full seed sieve

The specification of this spacer exceeds the processing size of the automatic filling and sieving machine, and cannot be adjusted, and the molecular sieve needs to be filled manually. Seal one end of the spacer with an insert, and seal the end of the insert with butyl rubber to prevent the molecular sieve from leaking at the port, see Figure 5 and Figure 6. A funnel was placed at the opening of the aluminum bar, and the molecular sieve was artificially poured into the aluminum bar through the funnel. Ensure that the filling amount of molecular sieve in the aluminum strip is greater than 75%. Note that the molecular sieve must be sealed after filling the sieve to prevent the molecular sieve from becoming invalid. Before the next use, use a vacuum cleaner to suck away the surface molecular sieve to prevent the invalid molecular sieve from being poured into the spacer. After filling the molecular sieve, assemble the four sides into a complete spacer.

^{Figure 5 Insulating glass molecular sieve filling}

^{Figure 6 Install the insulating glass aluminum bar frame}

2.4 Coating butyl rubber

At present, the common insulating glass butyl rubber machine on the market does not have the processing capacity of 50mm wide spacers, and the butyl rubber machine can be used for gluing through the transformation of the equipment. First remove the railing devices on both sides of the conveyor belt of the insulating glass butyl rubber coating machine, so that the spacer can be transported on the conveyor belt. Then adjust the nozzle to a width of more than 50mm so that it can allow the spacer to pass through. Then adjust the height of the glue nozzle according to the thickness of the aluminum strip, so that the glue outlet position can be at a suitable height on both sides of the spacer when coating. After the butyl rubber coating is completed, the frame is normally framed on the frame table.

^{Figure 7 Insulating glass butyl rubber coating machine before adjustment}

^{Figure 8 After adjustment of the insulating glass butyl rubber coating machine}

2.5 Lower film sealant

Attention should be paid to the sealing of the lower film, and the film should be facing up, to observe the glass film lamination and ensure the airtightness of the insulating glass. Seal the two sides of the spacer with glue to ensure that there are no air bubbles, and then use a shovel to scrape the back of the aluminum bar flat. Ensure that the structural adhesive is smooth and free of residual adhesive.

^{Figure 9 The insulating glass butyl rubber film}

^{Figure 10 The processing of Insulating glass sealant sealing} 

3. Precautions for installation

3.1 Cutting of spacers

Mainly pay attention not to affect the surface quality of the spacer during the cutting process, remove the cutting aluminum scraps in time and prepare the spacer to prevent scratches during the transfer process.

3.2 Filling the desiccant sieve

Select the pore size of the molecular sieve to be larger than the pore size of the reserved adsorption holes of the spacer. During the process of filling the full sieve and forming the frame, pay attention not to crush the molecular sieve to leave powder, to prevent the powder from falling into the hollow chamber through the reserved hole. The insert needs to be blocked with butyl rubber to prevent the molecular sieve powder from falling into the Yijing chamber through the corner interface.

3.3 Upper the aluminum frame

The weight of the spacers filled with molecular sieves is relatively heavy, and the frame may fall when the automatic laminating plate is used to press the production line. Furthermore, it is required to press the spacer bar onto one of the two pieces of coated glass by hand after framing and before assembling, to prevent the spacer bar from sliding down before assembling and causing deviation of the butyl rubber film.

3.4 Plate pressing and argon-gas filling

The LIJIANG Glass large-format insulating glass production line can be used for plate pressing and bonding. LIJIANG Glass adopts a double-plate pressing design structure and an adjustable matrix-separated plate pressing system to keep the plate pressing surface straight. Two plates are pressed to form a insulating glass, and an inert gas (usually argon-gas) is filled upward from the bottom of the two pieces of glass; when the inert gas is filled (the gas concentration reaches more than 90%), the two pieces of glass are pressed again combine.

^{Figure 11 The LIJIANG Glass large-format insulating glass production line 1}

3.5 Sealant sealing

The spacer is too wide to be sealed at the same time. The left and right sides are sealed separately. Pay attention to check the indoor and outdoor sides for quality defects such as airlines and air bubbles. After the two sides are sealed, use a spatula to level the middle.

4. The summary

Insulating glass with spacers with a width of 50 mm or less can be mass-produced automatically, and insulating glass with a spacer with a width of 50 mm or more can be controlled by the processing techniques described in this article. In addition, after measurement and mass production test, the production and processing process of the super large spacer insulating glass with a width of 50mm or more introduced in this article can ensure that the glass performance is the same as that of the insulating glass produced by ordinary continuous bending. The Dew point test and the four-character test Are qualified to meet customer needs.

^{For more information about LIJIANG Glass insulating glass processing equipment and insulating glass processing accessories, please click here to learn more.}