Forel introduces Thermoplastic spacer applicator

Company News
Forel introduces
Thermoplastic
spacer applicator
Revolutionising Insulating Glass Production With
Precision & Efficiency
Forel brings Thermoplastic spacer applicator to complete
the range of solutions dedicated to the production of
insulating glass.
To complete the range of
solutions dedicated to the
production of insulating
glass, Forel has introduced the
Thermoplastic spacer applicator
in the IG line. The applicator
plays a crucial role in the process,
tasked with accurately pumping
Thermoplastic material from the
barrel and extruding it directly onto
the glass plates. Comprising several
key components, the applicator
module includes several elements.
First of all, a high-performance
heated Graco pump ensures a
continuous flow of material by
feeding a storage reservoir, thereby
facilitating uninterrupted extrusion
even during drum changes.
A dual volumetric dosing system
driven by servo motors is utilized,
enabling precise control over the
amount of material dispensed.
A specially designed nozzle
ensures precise application of the
material onto the glass surface.
Also, a precise multipoint heated
delivery system is implemented,
maintaining the material at an
optimal application temperature
ranging from 120°C to 130°C.
CNC-controlled application,
with three-axis movement, allows
for precise and programmable
application patterns tailored to
specific requirements.
Finally, the integration of a
synchronized, dynamic suction cup
mechanism ensures a controlled
conveyance of the glass plates during
the application process, enhancing
precision and consistency.
Together, these elements form
a sophisticated applicator system
capable of delivering precise, highquality
application of Thermoplastic
material onto glass plates, meeting
the stringent standards of the
industry.
The pumping system for
thermoplastic employed by Forel
is integral to the manufacturing
process, ensuring precise and
efficient application onto glass
surfaces. Here’s an overview of its
components and functionalities:
The main Graco Pump System,
with a robust 200-litre capacity
stock, serves as the primary
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FOREL SPA • 2
component, securely affixed to Forel’s
pneumatic/hydraulic frame and
barrel support structure. This system
provides the necessary force to pump
the thermoplastic material through
the production line.
The heated thermal drum jacket,
integrated directly into the machine,
plays a crucial role in maintaining a
consistent and optimal temperature
for the thermoplastic material stored
in barrels. This ensures smooth
extrusion and application onto the
glass plates.
At this stage, the main drum pump
channels the Thermoplastic material
directly into the onboard reservoir
system, ensuring a continuous and
steady supply during the production
process.
Comprising two 7-litre cylindrical
storage containers linked to a
hydraulic pump, the reservoir pump
system serves as a backup, providing
a total reserve capacity of 14 litres.
This setup allows for approximately
30 minutes of continuous material
extrusion under typical operating
conditions, ensuring uninterrupted
workflow.
Characterised by precision and
accuracy, the dosing system consists
of two 0.6-litre cylindrical storage
containers driven by servo motors.
This system precisely controls the
volume of Thermoplastic material
dispensed, ensuring consistent
application onto the glass surfaces.
Directly connected to the application
nozzle, it facilitates smooth and
controlled material flow, resulting in
high-quality finishes.
The Nozzle
Achieving a hermetically sealed
start and finish point for the spacer
application is paramount to ensuring
the high quality and durability of the
thermoplastic Insulated Glass (IG)
unit. Here are the key features and
benefits of the sealing process:
The joint closing process utilizes
a well-established wedge joint
method, ensuring a gas-tight seal
that remains secure throughout the
lifespan of the IG unit. This minimizes
the loss of gas over time, contributing
to its longevity and performance.
With no requirement for secondary
touch-ups, the sealed joints maintain
their integrity without the need for
additional interventions. This reduces
maintenance efforts and enhances
operational efficiency.
The sealing process delivers
consistent reliability and aesthetic
appeal, with no tooling marks or
inconsistencies. This results in a
uniform and professional finish that
meets stringent quality standards.
Versatility: The sealed joints can
be positioned in corners or offset on
edges, offering flexibility in design
and application to suit various
architectural requirements and
preferences.
Moreover, the nozzle design
enhances efficiency and assembly
times:
Material Reduction: Compared to
typical standard nozzles, the nozzle
design reduces material usage,
optimizing resource utilization and
minimizing waste. This contributes
to cost savings and environmental
sustainability.
Reduced Assembly Times:
Assembly times are significantly
reduced by over 20% compared to
standard IGU equipment from Forel,
thanks to the nozzle’s innovative
design and improved efficiency.
Width and Radius Optimization:
The nozzle widths and corner radius
are optimized to improve sightlines
and reduce the spacer profile
height to 5.3 mm, enhancing the
aesthetic appeal of the IG units while
maintaining structural integrity.
Overall, the sealing process
and nozzle design represent
advancements in thermoplastic IG
unit technology, offering improved
performance, efficiency, and
aesthetics for the flat glass and
insulated glass industry.
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For enquiries on Forel products in
India, please write to Thorngate Sales
Corp at sales@thorngate.in
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Email: info@forelspa.com
Website: www.forelspa.com
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