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Insertion Equipment
In order to manufacture an Insulbar product line, one needs a set of Insertion Equipment to assemble the aluminum extrusions and the Insulbar profiles. The basic function of the insertion equipment is as follows:
Knurling of the Aluminum Cavity The first step in the insertion process is the knurling of the aluminum cavity. The aluminum cavity is knurled to aid in the creation of the mechanical lock between the Insulbar profile and the aluminum cavity. Without a proper knurl on the aluminum cavity, one cannot hope to achieve a sufficient shear strength to manufacture a quality fenestration product. The inner and outer sidewalls of the aluminum cavity are notched during the knurling process. The creation of the sharp notches on the sidewall of the aluminum allows the aluminum to grab and hold onto the Insulbar profile during the rolling step of the insertion process.
With proper knurling on the aluminum cavity, your Insulbar profile will have a high enough shear strength to provide a quality product that will last for years.
Types of Knurling
Each knurling wheel can notch about four million feet of aluminum extrusions before it is recommended for them to be changed. Plus, the notches on the rolling wheels can be resharpened and then reused. Insertion of the Insulbar Profile Once the aluminum cavity has been knurled, the next step in the insertion process is to insert the Insulbar profiles into their respective aluminum cavities. This can be done either by hand or by machine. Your manpower and your throughput requirements will determine which method you use. The start up method for inserting Insulbar profiles into their aluminum cavities is to slide the profiles in by hand. During initial startup and manufacturing, volumes are usually low and throughput requirements are not that great, so inserting by hand usually enables a manufacturer to meet demand. However, as demand grows, a window manufacturer will need to find a more efficient way to install the profiles.
The assembly machine increases throughput by allowing both Insulbar profiles to be inserted at the same time. The machine also lines up the aluminum, inserting the Insulbar into both halves of the aluminum extrusions so that the composite section is now ready for the rolling process Rolling of the Aluminum-Insulbar Composite Section The final step in the insertion process is the rolling of the Aluminum-Insulbar composite sections. The aluminum cavity has already been knurled and the Insulbar profiles are inserted into the top and bottom halves of the aluminum extrusions. We now have one composite section consisting of two aluminum extrusions and, generally, two Insulbar profiles.
In an Insulbar system, some finishing processes can be done after the rolling process is completed. Finishing processes such as anodizing and some painting will not adversely affect how the system will perform in the field, depending on the maximum temperature reached during baking. The Insulbar thermal break will take temperatures up to 400°F for short time periods. Several finishes can be applied to the aluminum after the Insulbar has been installed and the mechanical lock between the aluminum and the Insulbar has been established, although Kynar finishes cannot be added after the Insulbar is installed. These other finishes will not harm the shear strength of the fenestration product with the Insulbar inserted.
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The knurling machine notches the aluminum cavity on both sides by using a set of knurling wheels with notches on the wheels. The wheels are made out of hardened steel that, when rolled into the soft aluminum, creates the notches to hold the Insulbar in place. 
Automatic assembly machines then become the most economical and efficient means to install Insulbar into aluminum cavities. The assembly machine inserts the Insulbar by using notched wheels to grab hold of the Insulbar and drag it into the aluminum while the aluminum is held stationary. 
When the combined composite section passes through the rolling machine, the notches on the aluminum cavity are forced into the Insulbar thermal break, creating a mechanical lock that holds the composite section together. The rolling machine works by using a series of steel discs that pass the aluminum through the machine, pushing the aluminum into the Insulbar. Since the aluminum is wider than the space between the rolling wheels, the sidewalls of the aluminum cavity with the notches from the knurling machine are forced into the Insulbar as the composite is pushed through the rolling machine. Once the aluminum-Insulbar composite goes through the rolling machine, the process is complete and the composite section is now ready for use in any fenestration product. There is no set-up or curing time with an Insulbar production line.
