Processing flexible spacer material requires maximum precision. The material is fed from the coil and must be guided, punched, and applied precisely throughout the entire process. In practice, several challenges have emerged: inaccurate application, inconsistent butyl application, time-consuming changeovers, and limited flexibility across different spacer types. The solution? The new FSA-A from LiSEC.
Where do FLEXIBLE SPACERs SHOW their STRENGTHS?
Flexible spacers are particularly advantageous wherever function, design, and stability all play an important role:
- Large façade elements
- Applications with high optical requirements
- Constructions with increased inherent stability
Thanks to precise processing with the FSA-A, these advantages can now be realised much more easily and with greater process reliability. The goal was to consistently address existing challenges and create a system that impresses both technically and in daily operation. This involved not just minor adjustments, but a comprehensive redesign of nearly all relevant modules.
KEY IMPROVEMENTS AT A GLANCE
1. PRECISE BUTYL APPLICATION
Instead of relying on pressure systems as before, dosing is now carried out via a gear pump. This allows the butyl application to be controlled volumetrically with high accuracy. The result is a consistent and clean application, which not only improves gas tightness but also reduces contamination within the machine. At the same time, the precise start and stop behaviour ensures a significantly more uniform visual appearance.
2. OPTIMISED PUNCHING QUALITY
The quality of punching plays a crucial role, particularly at the corners. This is where it becomes evident whether a finished element appears clean and high-quality. Improvements in punching technology result in clearly defined geometries, delivering both technical and visual benefits—especially in demanding façade applications.
3. STABLE AND PRECISE MATERIAL TRANSPORT
In addition to the processing itself, the material flow within the system has also been redesigned. The transport of the flexible spacer to the application is now performed via a caterpillar feed, ensuring full-surface guidance of the material. This stabilises movement and enables significantly more precise positioning. Combined with integrated length compensation, consistent high quality is ensured even in dynamic processes and at high cycle rates.
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| Spacer feed including length compensation | Length compensation before application head |
3. SIGNIFICANTLY SIMPLIFIED CHANGEOVER
The new modular material magazine enables easy expansion to multiple spacer types while ensuring optimal climatic storage conditions. This maintains consistent material quality and allows the system to adapt to varying production requirements.
5. EFFICIENT PRODUCTION THROUGH DOUBLE-LANE OPERATION
A particular advantage remains the dual-lane technology, which shows its strengths especially in more complex glass structures. Different spacer geometries can be processed without interruption, which is particularly relevant for triple glazing with varying distances. The process remains continuously efficient, without time loss due to changeovers.
6. INTELLIGENT PROCESS MONITORING
Protective films and punching residues are centrally collected and automatically removed, while monitoring ensures that processes such as film removal function correctly. This increases transparency and prevents typical disruptions during operation.
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| Protective film extraction unit | Extraction unit |
7. MAINTENANCE AND ACCESSIBILITY
The FSA-A has been designed so that key assemblies are significantly easier to access compared to previous generations. In particular, the butyl unit can be fully opened, allowing cleaning and service work to be carried out quickly and without cumbersome handling. This not only reduces maintenance time but also minimises downtime during operation.
AVAILABILITY & FURTHER INFORMATION
The FSA-A is already available and successfully in use in initial applications. It has quickly proven itself in real production environments and is already being used for ongoing orders. Further information and contact options can be found here.
Summary
The FSA-A demonstrates how the processing of flexible spacer can be significantly simplified and improved through consistent further development. Precision, stability, and ease of use work hand in hand to deliver a process that excels both technically and in everyday operation.
