System Integration of Frame and Glass

Stephen Field & Michael Glover, Intra Product Development

To provide for continuous line production from glass/frame profile cutting to window assembly, our company has developed a new fenestration system that integrates frame and glass technology. The proprietary system features two new core technologies, which are trade named Friction Corner Welding and Fusion Assembly Systems.

Friction Corner Welding is "a rapid means of joining thermoplastic profiles" and involves the use of a corner web that is vibrated back and forth very rapidly. The framing profiles are pressured against the web, generating heat and melting plastic to form a welded joint. Through the incorporation of various design features into the web, mechanical flash removal is eliminated and this allows for welding around insulating glass (IG) units. With this fast heat friction process, the overall cycle time is 85 per cent less than with conventional hot plate welding,

Fusion Assembly is "the technology of glass and frame integration". Using a U-channel profile, the welded frame assembly is continuously adhered to both sides of the IG unit using twin sealant beads. By stiffening the frame through the adhered IG unit, structural performance is enhanced and this results in simplified profile design and reduced material use. By eliminating the use glazing stops, there are further material and labour cost savings.

Each core technology has required the development of two new pieces of automated equipment that has been engineered in partnership with two European equipment manufacturers, Bystronic Glass and Sturtz Machinery. These two new pieces of automated equipment have been designed to link to IG production and provide for high volume production of 800 sash frame window assemblies per eight-hour shift.

For the architectural market, the combination of Friction Corner Welding and Fusion Assembly allows for the development of new fenestration products that feature advanced composite thermoplastic frame materials.

Full-Text Article [251 KB]